2002 DTC INDEX Corolla

2002 DTC INDEX Corolla

AIR BAG RESTRAINT DTCS (A00150677)

NOTE: Retrieval of some diagnostic codes may require the use of special OEM tester or flash method using instrument cluster indicator. For procedures/testing of codes not shown below, refer to appropriate system article.

AIR BAG RESTRAINT DIAGNOSTIC TROUBLE CODE (DTC) IDENTIFICATION DTC Description DTC B0100 SHORT IN DRIVER-SIDE AIR BAG MODULE SQUIB CIRCUIT DTC B0101 OPEN IN DRIVER-SIDE AIR BAG MODULE SQUIB CIRCUIT DTC B0102 DRIVER-SIDE AIR BAG SQUIB CIRCUIT SHORT TO GROUND DTC B0103 DRIVER-SIDE AIR BAG SQUIB CIRCUIT SHORT TO BATTERY DTC B0105 SHORT IN PASSENGER-SIDE AIR BAG SQUIB CIRCUIT DTC B0106 OPEN IN PASSENGER-SIDE AIR BAG SQUIB CIRCUIT DTC B0107 SHORT TO GROUND IN PASSENGER-SIDE AIR BAG SQUIB CIRCUIT DTC B0108 SHORT TO BATTERY IN PASSENGER-SIDE AIR BAG SQUIB CIRCUIT DTC B0110 SHORT IN RIGHT-SIDE AIR BAG MODULE SQUIB CIRCUIT DTC B0111 OPEN IN RIGHT-SIDE AIR BAG MODULE SQUIB CIRCUIT DTC B0112 SHORT TO GROUND IN RIGHT-SIDE AIR BAG MODULE SQUIB CIRCUIT DTC B0113 SHORT TO BATTERY IN RIGHT-SIDE AIR BAG MODULE SQUIB CIRCUIT DTC B0115 SHORT IN LEFT-SIDE AIR BAG MODULE SQUIB CIRCUIT DTC B0116 OPEN IN LEFT-SIDE AIR BAG MODULE SQUIB CIRCUIT DTC B0117 SHORT TO GROUND IN LEFT-SIDE AIR BAG MODULE SQUIB CIRCUIT DTC B0118 SHORT TO BATTERY IN LEFT-SIDE AIR BAG MODULE SQUIB CIRCUIT DTC B0130 SHORT IN PASSENGER-SIDE SEAT BELT PRETENSIONER SQUIB CIRCUIT

2002 DTC INDEX Corolla

DTC B0131 DTC B0132 DTC B0133 DTC B0135 DTC B0136 DTC B0137 DTC B0138 DTC B1100 DTC B1140 DTC B1141 DTC B1156 & B1157 DTC B1158 & B1159

OPEN IN PASSENGER-SIDE SEAT BELT PRETENSIONER SQUIB CIRCUIT SHORT TO GROUND IN PASSENGER-SIDE SEAT BELT PRETENSIONER SQUIB CIRCUIT SHORT TO BATTERY IN PASSENGER-SIDE SEAT BELT PRETENSIONER SQUIB CIRCUIT SHORT IN DRIVER-SIDE SEAT BELT PRETENSIONER SQUIB CIRCUIT OPEN IN DRIVER-SIDE SEAT BELT PRETENSIONER SQUIB CIRCUIT SHORT TO GROUND IN DRIVER-SIDE SEAT BELT PRETENSIONER SQUIB CIRCUIT SHORT TO BATTERY IN DRIVER-SIDE SEAT BELT PRETENSIONER SQUIB CIRCUIT AIR BAG SENSOR ASSEMBLY MALFUNCTION RIGHT-SIDE AIR BAG SENSOR ASSEMBLY MALFUNCTION LEFT-SIDE AIR BAG SENSOR ASSEMBLY MALFUNCTION RIGHT FRONT AIR BAG SENSOR MALFUNCTION LEFT FRONT AIR BAG SENSOR MALFUNCTION

AUTOMATIC TRANSMISSION DTCS (A00140973)

AUTOMATIC TRANSMISSION DIAGNOSTIC TROUBLE CODE (DTC) IDENTIFICATION DTC Description P0500 Vehicle Speed Sensor P0750 No. 1 Solenoid (Perform appropriate solenoid test under COMPONENT TESTS) P0753 No. 1 Solenoid Circuit Malfunction P0755 No. 2 Solenoid (Perform appropriate solenoid test under COMPONENT TESTS) P0758 No. 2 Solenoid Circuit Malfunction P0770 Lock-Up Solenoid (Perform appropriate solenoid test under COMPONENT TESTS) P0773 Lock-Up Solenoid Circuit Malfunction P1520 Brakelight Switch Signal P1780 Park/Neutral Position Switch Malfunction

ENGINE PERFORMANCE DTCS (A00133205)

2002 DTC INDEX Corolla

ENGINE PERFORMANCE DIAGNOSTIC TROUBLE CODE (DTC) IDENTIFICATION DTC Description P0100 Mass Airflow Meter Circuit P0101 Mass Airflow Meter Circuit Range/Performance P0110 Intake Air Temperature Sensor Circuit P0115 Engine Coolant Temperature Sensor Circuit P0116 Engine Coolant Temperature Sensor Circuit Range/Performance P0120 Throttle Position (TP) Sensor Circuit P0121 Throttle Position (TP) Sensor Circuit Range/Performance P0125 Insufficient Coolant Temperature For Closed Loop Fuel Control P0128 Thermostat Malfunction P0130 Heated Oxygen Sensor No. 1 Circuit P0133 Heated Oxygen Sensor No. 1 Circuit Slow Response P0135 Heated Oxygen Sensor No. 1 Heater Circuit P0136 Heated Oxygen Sensor No. 2 Circuit P0141 Heated Oxygen Sensor No. 2 Heater Circuit P0171 System Too Lean P0172 System Too Rich P0300 Random Misfire Detected P0301 Cylinder No. 1 Misfire Detected P0302 Cylinder No. 2 Misfire Detected P0303 Cylinder No. 3 Misfire Detected P0304 Cylinder No. 4 Misfire Detected P0325 Knock Sensor Circuit P0335 Crankshaft Position Sensor Circuit P0340 Camshaft Position Sensor Circuit P0420 Catalyst System Efficiency Below Threshold P0440 Evaporative Emission Control System P0441 Incorrect EVAP Purge Flow P0442 Evaporative Emission Control System Leak Detected P0446 EVAP Vent Control Circuit P0450 EVAP Pressure Sensor Circuit P0451 EVAP Pressure Sensor Range/Performance P0500 Vehicle Speed Sensor Circuit P0505 Idle Air Control (IAC) System Circuit P1300 Ignitor No. 1 Circuit P1305 Ignitor No. 2 Circuit P1310 Ignitor No. 3 Circuit P1315 Ignitor No. 4 Circuit P1335 Crankshaft Position Sensor Circuit P1346 Variable Valve Timing Circuit Range/Performance P1349 Variable Valve Timing System Malfunction P1520 Stoplight Switch Signal Circuit (A/T Only) P1600 ECM BATT Circuit

2002 DTC INDEX Corolla

P1656 P1780

Oil Control Valve Malfunction Park/Neutral Position Switch Circuit (A/T Only)

2002 SPECIFICATIONS INDEX Corolla

2002 SPECIFICATIONS INDEX Corolla

SPECIFICATIONS INDEX
COROLLA SPECIFICATIONS INDEX System Air Conditioning Service Torque Axle Shaft/Bearing Lock Nut/Drive Axle Nut (Front) Axle Hub-To-Axle Carrier Bolts (Rear) Battery Brakes Bleeding Sequence Disc & Drum Brakes Torque Charging Generator Torque Drive Belts Adjustment Belt Routing Engine Cooling General Service Specifications Radiator Cap Pressure Thermostat R & I Water Pump R & I Engine Mechanical Compression Oil Pressure At Idle Speed At 3,000 RPM Overhaul Torque Fluid Specifications Flywheel/Flex Plate (Drive Plate) Torque A/T M/T Specification/Procedure SPECIFICATIONS TORQUE SPECIFICATIONS 166 ft.lbs (225 N.m) 59 ft.lbs (80 N.m) NA BLEEDING BRAKE SYSTEM DISC & DRUM BRAKE SPECIFICATIONS TORQUE SPECIFICATIONS ON-VEHICLE INSPECTION TORQUE SPECIFICATIONS BELT ADJUSTMENT DRIVE BELT ROUTING COOLING SYSTEM SPECIFICATIONS 10.7-14.9 psi (.75-1.05 kg/cm2 ) Minimum opening pressure is 8.5 psi (.59 kg/cm2 ) THERMOSTAT WATER PUMP ENGINE COMPRESSION 4.3 psi (0.3 kg/cm2 ) or more 43-78 psi (3.0-5.5 kg/cm2 ) ENGINE SPECIFICATIONS TORQUE SPECIFICATIONS See FLUIDS under MAINTENANCE tab. 61 ft.lbs (83 N.m) Step 1) 36 ft.lbs (49 N.m)

2002 SPECIFICATIONS INDEX Corolla

Step 2) additional 90 degree turn Fuel System Pressure Specification Fuel Pressure Test Procedure Fuel Filter Location Ignition Firing Order & Cylinder Identification Ignition Wires (Resistance) Ignition Wires (Routing) Spark Plug Type Gap Torque Starting Starter Torque Wheel Alignment Adjustment Specifications Torque Wheel & Tire Wheel Lug Nut Torque STARTER SPECIFICATIONS TORQUE SPECIFICATIONS SPECIFICATIONS Refer to applicable components under PROCEDURES . 76 ft.lbs (103 N.m) 44-50 psi (3.1-3.5 kg/cm2 ) CELICA, COROLLA, ECHO & MR2 FUEL FILTER FIRING ORDER & CYLINDER IDENTIFICATION HIGH TENSION WIRE RESISTANCE NA NGK No. IFR5A11 DENSO No. SK16R11 .043 In. (1.10 mm) 13 ft.lbs (18 N.m)

2002 ACCESSORIES & EQUIPMENT Body Electrical/Troubleshooting - Corolla

2002 ACCESSORIES & EQUIPMENT Body Electrical/Troubleshooting - Corolla

BODY ELECTRICAL SYSTEM

PRECAUTION NOTE: Take care to observe the following precautions when performing inspections or removal and replacement of body electrical related parts.

1. HEADLIGHT SYSTEM Halogen bulbs have pressurized gas inside and require special handling. They can burst if scratched or dropped. Hold a bulb only by its plastic or metal case. Don't touch the glass part of a bulb with bare hands. 2. SRS (SUPPLEMENTAL RESTRAINT SYSTEM) The COROLLA is equipped with an SRS (Supplemental Restraint System) such as the driver airbag and front passenger airbag. Failure to carry out service operation in the correct sequence could cause the SRS to unexpectedly deploy during servicing, possibly leading to a serious accident. Before servicing (including removal or installation of parts, inspection or replacement), be sure to read the precautionary notices in the RS section. 3. AUDIO SYSTEM If the negative (-) terminal cable is disconnected from the battery, the preset AM, FM 1 and FM 2 stations stored in memory are erased, so be sure to note the stations and reset them after the negative (-) terminal cable is reconnected to the battery. 4. MOBILE COMMUNICATION SYSTEM If the vehicle is equipped with a mobile communication system, refer to PRECAUTIONS .

TROUBLESHOOTING
PROBLEM SYMPTOMS
Ignition Switch And Key Unlock Warning Switch

IGNITION SWITCH & KEY UNLOCK WARNING SWITCH Symptom/Suspect Area Ignition Switch Is Not Set To Each Position Ignition Switch "Key Unlock Warning System" Does Not Operate GAUGE Fuse Key Unlock Warning Switch

See
(1) (2) (1)

2002 ACCESSORIES & EQUIPMENT Body Electrical/Troubleshooting - Corolla

Door Courtesy Switch Integration Relay (I/P J/B) Wire Harness (1) INSPECTION
(2) FUSES & CIRCUIT BREAKERS (3) INSPECTION

(3) (1)

.....

Headlight System (Except Taiwan)

HEADLIGHT SYSTEM (EXCEPT TAIWAN) Symptom/Suspect Area Headlight Does Not Light. (Taillight Is Normal) Wire Harness Headlight Does Not Light (Taillight Does Not Light Up) Wire Harness Only One Side Light Does Not Light Headlight Bulb Head (LH-LWR, RH-LWR) Fuse (E/G Room No. 5 J/B) Wire Harness "Lo-Beam" Does Not Light Headlight Bulb Head (LH-1NR, RH-LWR) Fuse (E/G Room No. 5 J/B) Headlight Control Relay (E/G Room No. 2 J/B) Integration Relay (I/P J/B) Light Control Switch Wire Harness "Hi-Beam" Does Not Light Headlight Bulb Head (LH) Or Head (LH-UPR) Fuse (E/G Room No. 2 J/B) Head (RH) Or Head (RH-UPR) Fuse (E/G Room No. 2 J/B) DRL Fuse (E/G Room No. 5 R/B) Headlight Dimmer Relay (E/G Room No. 5 J/B) Daytime Running Light Relay (E/G Room No. 6 R/B) Daytime Running Light Relay (Main) Headlight Dimmer Switch Wire Harness "Flash" Does Not Light Headlight Bulb Head (LH) Or Head (LH-UPR) Fuse (E/G Room No. 2 J/B) Head (RH) Or Head (RH-UPR) Fuse (E/G Room No. 2 J/B)

See ..... ..... .....

(1)

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(1) (2) (2) (2)

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(1) (1) (1) (2) (2) (2) (2)

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(1) (1)

2002 ACCESSORIES & EQUIPMENT Body Electrical/Troubleshooting - Corolla

DRL Fuse (E/G Room No. 5 R/B) Headlight Dimmer Relay (E/G Room No. 5 J/B) Daytime Running Light Relay (E/G Room No. 6 R/B) Daytime Running Light Relay (Main) Headlight Dimmer Switch Wire Harness "Light-On Warning System" Does Not Operate GAUGE Fuse (I/P J/B) DOME Fuse (E/G Room No. 2 JB) Integration Relay (I/P J/B) Door Courtesy Switch (Driver's) Ignition Switch Wire Harness Headlight Does Not Light With Engine Running And Light Control SW In OFF Headlight Bulb GAUGE Fuse (I/P J/B) HEAD (LH) Or HEAD (LH-UPR) Fuse (E/G Room No. 2 J/B) HEAD (RH) Or HEAD (RH-UPR) Fuse (E/G Room No. 2 J/B) Daytime Running Light Relay (Main) Wire Harness Other Parts
(1) FUSES & CIRCUIT BREAKERS (2) INSPECTION (3) INSPECTION (4) INSPECTION (5) Terminal L of generator and parking brake switch.

(1) (2) (2) (2) (2)

.....
(1) (1) (2) (3) (4)

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(1) (1) (1) (2)

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(5)

Headlight System (Taiwan)

HEADLIGHT SYSTEM (TAIWAN) Symptom/Suspect Area Headlight Does Not Light (Taillight Is Normal) Wire Harness Headlight Does Not Light. (Taillight Does Not Light Up) Wire Harness Only One Side Light Does Not Light Headlight Bulb HEAD (LH) Or HEAD (LH-UPR) Fuse (E/G Room No. 2 JIB) HEAD (RH) Or HEAD (RH-UPR) Fuse (E/G Room No. 2 J/B)

See ..... ..... .....

(1) (1)

2002 ACCESSORIES & EQUIPMENT Body Electrical/Troubleshooting - Corolla

Wire Harness "Lo-Beam" Does Not Light Headlight Bulb HEAD (LH) Or HEAD (LH-UPR) Fuse (E/G Room No. 2 JIB) HEAD (RH) Or HEAD (RH-UPR) Fuse (E/G Room No. 2 JIB) Headlight Control Relay (E/G Room No. 2 JIB) Light Control Switch Wire Harness "Hi-Beam" Does Not Light Headlight Bulb HEAD (LH) Or HEAD (LH-UPR) Fuse (E/G Room No. 2 JIB) HEAD (RH) Or HEAD (RH-UPR) Fuse (E/G Room No. 2 JIB) Headlight Control Relay (E/G Room No. 5 JIB) Headlight Dimmer Switch Wire Harness "Flash" Does Not Light Headlight Bulb HEAD (LH) Or HEAD (LH-UPR) Fuse (E/G Room No. 2 JIB) HEAD (RH) Or HEAD (RH-UPR) Fuse (E/G Room No. 2JB) Headlight Control Relay (E/G Room No. 5 JIB) Headlight Dimmer Switch Wire Harness "Light-On Warning System" Does Not Operate GAUGE Fuse (I/P J/B) DOME Fuse (E/G Room No. 2 JB) HEAD (LH) Or HEAD (LH-UPR) Fuse (E/G Room No. 2 J/B) HEAD (RH) Or HEAD (RH-UPR) Fuse (E/G Room No. 2 J/B) Integration Relay (IIP J/B) Door Courtesy Switch (Driver's) Ignition Switch Wire Harness Headlight Does Not Light With Engine Running And Light Control SW In OFF Headlight Bulb GAUGE Fuse (I/P J/B) Wire Harness Other Parts
(1) FUSES & CIRCUIT BREAKERS (2) INSPECTION (3) INSPECTION

..... .....
(1) (1) (2) (2)

..... .....
(1) () (2) (2)

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(1) (1) (2) (2)

.....
(1) (1) (1) (1) (3) (4) (4)

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(1)

..... .....(5)

2002 ACCESSORIES & EQUIPMENT Body Electrical/Troubleshooting - Corolla

(4) INSPECTION (5) Terminal L of generator and parking brake switch.

Fog Light System

FOG LIGHT SYSTEM Symptom/Suspect Area Fog Light Does Not Light Up With Light Control SW TAIL Or HEAD (Headlight Is Normal) Bulb FOG Fuse (I/P JB) Fog Light Relay Fog Light Switch

See .....
(1) (2) (2)

Wire Harness ..... Fog Light Does Not Light Up With Light Control SW TAIL Or HEAD (Headlight Does Not Light) (3) Headlight and Taillight System Wire Harness Only One Fog Light Does Not Light Bulb Wire Harness (1) FUSES & CIRCUIT BREAKERS
(2) INSPECTION (3) HEADLIGHT SYSTEM (EXCEPT TAIWAN) Or HEADLIGHT SYSTEM (TAIWAN)

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Taillight System

TAILLIGHT SYSTEM Symptom/Suspect Area Taillight Does Not Light. (Headlight Does Not Light) Integration Relay (I/P J/B) Light Control Switch Wire Harness Taillight Does Not Light (Headlight Is Normal) TAIL Fuse (I/P J/B) Taillight Control Relay (I/P J/B) Integration Relay (I/PJ/B) Light Control Switch Wire Harness Only One Side Light Does Not Light Bulb Wire Harness Rear Combination Light Does Not Light

See
(1) (1)

.....
(2) (1) (1) (1)

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2002 ACCESSORIES & EQUIPMENT Body Electrical/Troubleshooting - Corolla

Bulb Wire Harness "Light-On Warning System" Does Not Operate GAUGE Fuse (I1P J/B) Integration Relay (I/P J/B) Door Courtesy Switch (Driver's) Wire Harness (1) INSPECTION
(2) FUSES & CIRCUIT BREAKERS (3) INSPECTION

..... .....
(2) (1) (3)

.....

Turn Signal And Hazard Warning System

TURN SIGNAL & HAZARD WARNING SYSTEM Symptom/Suspect Area "Hazard" And "Turn" Do Not Light Up Hazard Warning Switch Turn Signal Flasher Wire Harness The Flashing Frequency Is Abnormal Bulb Turn Signal Switch Wire Harness Hazard Warning Light Does Not Light (Turn Signal Is Normal Horn Fuse (Engine Room No. 2 J/B) Wire Harness Hazard Warning Light Does Not Light In One Direction Horn Fuse (Engine Room No. 2 J/B) Wire Harness
(3) Turn Signal Does Not Light Up

See
(1) (1)

..... .....
(1)

.....
(2)

.....
(2)

.....
(4) (2) (1)

Ignition Switch Turn Fuse (I/P J/B) Turn Signal Switch Wire Harness
(5) Turn Signal Does Not Light Up

.....
(2) (1)

Turn Fuse (I/P J/B) Turn Signal Switch Wire Harness Turn Signal Does Not Light In One Direction Turn Signal Switch

.....
(1)

2002 ACCESSORIES & EQUIPMENT Body Electrical/Troubleshooting - Corolla

Wire Harness Only One Bulb Does Not Light Up Bulb Wire Harness (1) INSPECTION
(2) FUSES & CIRCUIT BREAKERS (3) Combination meter, wiper and washer do not operate. (4) INSPECTION (5) Combination meter, wiper and washer are normal.

..... ..... .....

Interior Light System

INTERIOR LIGHT SYSTEM Symptom/Suspect Area Only One Interior Light Does Not Light Up Bulb Wire Harness Interior Light Does Not Light Up (All) Dome Fuse (E/G Room No. 2 J/B) Wire Harness Room Light Does Not Light Up Bulb Room Light Wire Harness Front Personal Light Does Not Light Up Bulb Front Personal Light Wire Harness Map Light Does Not Light Up Bulb Map Light Wire Harness Luggage Compartment Light Does Not Light Up Bulb Luggage Compartment Door Courtesy Switch Wire Harness (1) FUSES & CIRCUIT BREAKERS
(2) INSPECTION

See ..... .....

(1)

..... .....
(2)

..... .....
(2)

..... .....
(2)

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(2)

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Back-Up Light System

2002 ACCESSORIES & EQUIPMENT Body Electrical/Troubleshooting - Corolla

BACK-UP LIGHT SYSTEM Symptom/Suspect Area Back-Up Light Does Not Light Up GAUGE Fuse (I/P J/B) Ignition Switch Wire Harness Bulb Back-Up Light Remains Always On Back-Up Light Switch (M/X) Park/Neutral Position Switch (A/X) Wire Harness Only One Light Does Not Light Up Bulb Wire Harness (1) FUSES & CIRCUIT BREAKERS
(2) INSPECTION (3) INSPECTION (4) DTC P1780: PARK/NEUTRAL POSITION SWITCH

See
(1) (2)

..... .....
(3) (4)

..... ..... .....

Stop Light System

STOP LIGHT SYSTEM Symptom/Suspect Area Stop Light Does Not Light Up Stop Fuse (I/P J/B) Stop Light Switch Wire Harness Only One Light Always Lights Up Wire Harness Only One Light Does Not Light Bulb Wire Harness (1) FUSES & CIRCUIT BREAKERS
(2) INSPECTION

See
(1) (2)

..... ..... ..... .....

Wiper And Washer

WIPER AND WASHER Symptom/Suspect Area Wipers And Washers Do Not Operate Wiper Fuse (I/P J/B)

See
(1)

2002 ACCESSORIES & EQUIPMENT Body Electrical/Troubleshooting - Corolla

Wiper Switch Wiper Motor Wire Harness Wipers Do Not Operate In Lo Or Hi Position Wiper Switch Wiper Motor Wire Harness Wipers Does Not Operate In INT. Wiper Switch Wiper Motor Wire Harness Washer Motor Does Not Operate Washer Switch Washer Motor Wire Harness Wipers Do Not Operate When Washer Switch In On Washer Motor Wire Harness Washer Fluid Does Not Operate Washer Hose And Nozzle At Wiper Switch HI Position, The Wiper Blade Is In Contact With The Body

(2) (2)

.....
(2) (2)

.....
(2) (2)

.....
(2) (2)

.....
(2)

..... .....

(2) Wiper Switch (3) Wire Harness ..... When The Wiper Switch Is OFF, The Wiper Blade Does Not Retract Or The Retract Position Wrong

Wiper Switch (3) Wire Harness (1) FUSES & CIRCUIT BREAKERS
(2) INSPECTION (3) Inspect wiper arm and blade set position.

(2)

.....

Combination Meter
Meter Gauges and Illumination

COMBINATION METER (METER, GAUGES AND ILLUMINATION) Symptom/Suspect Area Tachometer, Fuel Gauge And Engine Coolant Temperature Gauge Do Not Operate GAUGE Fuse (I/P J/B) Meter Circuit Plate Wire Harness Speedometer Does Not Operate

See
(1) (2)

.....

2002 ACCESSORIES & EQUIPMENT Body Electrical/Troubleshooting - Corolla

Vehicle Speed Sensor Meter Circuit Plate Wire Harness Tachometer Does Not Operate Igniter (IG Section) Meter Circuit Plate Wire Harness Fuel Gauge Does Not Operate Or Abnormal Operation Fuel Receiver Gauge Fuel Sender Gauge Meter Circuit Plate Wire Harness Engine Coolant Temperature Gauge Does Not Operate Or Abnormal Operation Engine Coolant Temperature Receiver Gauge Engine Coolant Temperature Sender Gauge Meter Circuit Plate Wire Harness All Illumination Lights Do Not Light Up Tail Fuse Light Control Rheostat Wire Harness Brightness Does Not Change Even When Rheostat Turned Bulb Wire Harness Only One Illumination Light Does Not Light Bulb Wire Harness (1) FUSES & CIRCUIT BREAKERS
(2) GAUGES & INSTRUMENT PANELS (3) INSPECTION (4) IGNITION SYSTEMS -DTC 1300, 1305, 1310 & 1315
Warning Lights

(3) (2)

.....
(4) (2)

.....
(3) (3) (2)

.....
(3) (3) (2)

.....
() (3)

..... ..... ..... ..... .....

COMBINATION METER (WARNING LIGHTS) Symptom/Suspect Area Warning Light Do Not Light Up. (Except Discharge, Open Door and SRS). GAUGE Fuse (I/P J/B) Meter Circuit Plate Wire Harness

See
(1) (2)

.....

2002 ACCESSORIES & EQUIPMENT Body Electrical/Troubleshooting - Corolla

Fuel Level Warning Light Does Not Light Up. Bulb Fluid Level Warning Switch Meter Circuit Plate Wire Harness Low Oil Pressure Warning Light Does Not Light Up Bulb Low Oil Pressure Warning Switch Meter Circuit Plate Wire Harness ABS Warning Light Does Not Light Up Bulb ABS ECU Wire Harness Seat Belt Warning Light Does Not Light Up Bulb Seat Belt Buckle Switch Integration Relay (I/P J/B) Wire Harness Discharge Warning Light Does Not Light Up IGN Fuse (I/P J/B) Bulb Wire Harness Generator Brake Warning Light Does Not Light Up Bulb Parking Brake Switch Brake Fluid Level Warning Switch Bulb Check Relay Meter Circuit Plate Wire Harness SRS Warning Light Does Not Light Up ECU-B Fuse I/P J/B) Bulb AIRBAG Sensor Assembly Meter Circuit Plate Wire Harness Open Door Warning Light Does Not Light Up DOME Fuse (E/G Room No. 2 J/B) Bulb Door Courtesy Switch

.....
(3) (2)

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(3) (2)

..... .....
(4)

.....

(3) (3)

.....
(1)

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(3) (3) (3) (2)

.....
(1)

.....
(5) (2)

.....
(1)

.....
(6)

2002 ACCESSORIES & EQUIPMENT Body Electrical/Troubleshooting - Corolla

Meter Circuit Plate Wire Harness Washer Level Warning Light Does Not Light Up Bulb Washer Fluid Level Warning Switch Meter Circuit Wire Harness (1) FUSES & CIRCUIT BREAKERS
(2) GAUGES & INSTRUMENT PANELS (3) INSPECTION (4) ANTI-LOCK (5) AIR BAG RESTRAINT SYSTEMS (6) INSPECTION
Indicator Lights

(2)

..... .....
(3) (2)

.....

COMBINATION METER (INDICATOR LIGHTS) Symptom/Suspect Area O/D Off Indicator Light Does Not Light Up Bulb O/D Off Switch Meter Circuit Plate Wire Harness Cruise Control Indicator Light Does Not Light Up Bulb Cruise Control ECU Meter Circuit Plate Wire Harness High Beam Indicator Light Does Not Light Up Bulb Meter Circuit Plate Wire Harness Headlight System Turn Indicator Light Does Not Light Bulb Meter Circuit Plate Wire Harness Turn Signal And Hazard Warning System Shift Indicator Lights Do Not Light Up Bulb

See .....
(1) (2)

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(3) (2)

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(2)

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(4)

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(2)

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(4)

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2002 ACCESSORIES & EQUIPMENT Body Electrical/Troubleshooting - Corolla

Meter Circuit Plate Park/Neutral Position Switch Wire Harness Only One Shift Indicator Does Not Light Up Bulb Meter Circuit Plate Malfunction Indicator Light Does Not Light Up Bulb ECM Meter Circuit Plate Wire Harness Indicator Lights Do Not Light Up. (Except Turn, High Beam And Security). GAUGE Fuse (I/P J/B) Wire Harness (1) OVERDRIVE SWITCH
(2) GAUGES & INSTRUMENT PANELS HEADLIGHT AND TAILLIGHT SYSTEM (3) CRUISE CONTROL SYSTEMS (4) HEADLIGHT SYSTEM (EXCEPT TAIWAN) Or HEADLIGHT SYSTEM (TAIWAN) (5) DTC P1780: PARK/NEUTRAL POSITION SWITCH (6) BASIC DIAGNOSTIC PROCEDURES - 4-CYLINDER (7) FUSES & CIRCUIT BREAKERS

(2) (5)

..... .....
(2)

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(6) (2)

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(7)

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Defogger System

DEFOGGER SYSTEM Symptom/Suspect Area All Defogger Systems Do Not Operate DEFOG M-Fuse (I/P J/B) Defogger Relay (I/P J/B) Defogger Switch Wire Harness Rear Window Defogger Does Not Operate Defogger Wire Choke Coil Wire Harness (1) FUSES & CIRCUIT BREAKERS
(2) INSPECTION

See
(1) (2) (2)

.....
(2) (2)

.....

Power Window Control System

2002 ACCESSORIES & EQUIPMENT Body Electrical/Troubleshooting - Corolla

POWER WINDOW CONTROL SYSTEM Symptom/Suspect Area Power Window Does Not Operate (All) (Power Door Lock Does Not Operate) POWER M-Fuse (I/P J/B) Power Main Relay (I/P J/B) Wire Harness Power Window Does Not Operate (All) (Power Door Lock Is Normal) Ignition Switch Power Window Master Switch Wire Harness "One Touch Power Window System" Does Not Operate Power Window Master Switch Only One Window Glass Does Not Move Power Window Master Switch Power Window Switch Power Window Motor Wire Harness "Window Lock System" Does Not Operate Power Window Master Switch Key-Off Power Window Does Not Operate GAUGE Fuse (I/P J/B) Integration Relay (I/P J/B) Ignition Switch Door Courtesy Switch Wire Harness (1) FUSES & CIRCUIT BREAKERS
(2) INSPECTION (3) INSPECTION (4) INSPECTION

See
(1) (2)

.....
(3) (2)

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(2) (2) (2) (2)

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(2) (1) (2) (3) (4)

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Power Door Lock Control System

POWER DOOR LOCK CONTROL SYSTEM Symptom/Suspect Area "Door lock System" Does Not Operate At All Power M-Fuse (I/P J/B) CIG Fuse (I/P J/B) Door (I/P J/B) Integration Relay (I/P J/B) Wire Harness

See
(1) (1) (1) (2)

.....

2002 ACCESSORIES & EQUIPMENT Body Electrical/Troubleshooting - Corolla

Door Lock System Does Not Operate By Manual Switch Power Window Master Switch Door Lock Manual Switch Integration Relay (I/P J/B) Wire Harness Door Lock System Does Not Operate By Door Key Door Key Lock And Unlock Switch Integration Relay (I/P J/B) Wire Harness Door Lock Link Disconnects Fault In 2-Operation Unlock Function Of Drivers Door Key Lock And Unlock Switch Door Key Lock And Unlock Switch Integration Relay (I/P J/B) Wire Harness Fault In Key Confine Prevention Operation Integration Relay (I/P J/B) Key Unlock Warning Switch Door Courtesy Switch Wire Harness Only One Door Lock Does Not Operate Door Lock Motor Wire Harness (1) FUSES & CIRCUIT BREAKERS
(2) INSPECTION (3) INSPECTION

(2) (2) (2)

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(2) (2)

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(2) (2)

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(2) (3) (3)

.....
(2)

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Sliding Roof System

SLIDING ROOF SYSTEM Symptom/Suspect Area Sliding Roof System Does Not Operate (Door Lock Does Not Operate) Power M-Fuse (I/P J/B) Power Main Relay (I/P J/B) Wire Harness Sliding Roof System Does Not Operate (Door Lock Is Normal) Ignition Switch Sliding Roof Control Switch And Relay Sliding Roof Motor And Limit Switch Wire Harness Sliding Roof System Operates Abnormally

See
(1) (2)

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(3) (2) (2)

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2002 ACCESSORIES & EQUIPMENT Body Electrical/Troubleshooting - Corolla

Sliding Roof Control Switch And Relay Sliding Roof Motor And Limit Switch Wire Harness Sliding Roof System Stops Operation Half Way (Stones Or Foreign Sliding Roof Control Switch And Relay Sliding Roof Motor And Limit Switch Wire Harness "Key-Off Sliding Roof" Operation Does Not Operate DOME Fuse (E/G Room No. 2 JB) GAUGE Fuse (I/P J/B) Ignition Switch Integration Relay (I/P J/B) Wire Harness (1) FUSES & CIRCUIT BREAKERS
(2) INSPECTION (3) INSPECTION

(2) (2)

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(2) (2)

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(1) (1) (3) (2)

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Power Mirror Control System

POWER MIRROR CONTROL SYSTEM Symptom/Suspect Area Mirror Does Not Operate CIG Fuse (I/P J/B) Mirror Switch Mirror Motor Wire Harness Mirror Operates Abnormally Mirror Switch Mirror Motor Wire Harness (1) FUSES & CIRCUIT BREAKERS
(2) INSPECTION

See
(1) (2) (2)

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(2) (2)

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2002 ACCESSORIES & EQUIPMENT Cruise Control Systems - Corolla

2002 ACCESSORIES & EQUIPMENT Cruise Control Systems - Corolla

APPLICATION
CRUISE CONTROL APPLICATION VIN Code Engine Code R 1ZZ-FE Engine Type 4-Cylinder Displacement 1.8L

DESCRIPTION
WARNING: Vehicle is equipped with Supplemental Inflatable Restraint (SIR) system. When servicing vehicle, use care to avoid accidental air bag deployment. SIR system related components are located in various locations throughout interior and exterior of vehicle, depending on application. Do not use electrical test equipment on or near these circuits. Before attempting ANY repairs involving steering column, instrument panel or related components, or If necessary, deactivate SIR system before servicing components. See AIR BAG SAFETY PRECAUTIONS and DISABLING & ACTIVATING AIR BAG SYSTEM in AIR BAG RESTRAINT SYSTEMS article in RESTRAINTS. NOTE: For fuse locations, see FUSES & CIRCUIT BREAKERS article in ELECTRICAL.

System Outline The current is applied at all times through the STOP fuse to TERMINAL 2 of the stop light SW. For stop light switch terminal identification, see step 2 of DTC 12: ACTUATOR MAGNETIC CLUTCH CIRCUIT under DIAGNOSTIC TESTS. With the ignition SW turned to on, the current flows through the GAUGE fuse to TERMINAL 9 of the integration relay to terminal (A) 9 to Terminal (D) 2 of the combination meter and the current through the ECU-IG fuse flows to TERMINAL 9 of the cruise control ECU. See Fig. 1 . When the ignition SW is on and the cruise SW is turned on, see Fig. 2 , a signal is input from TERMINAL 5 of the cruise control SW to TERMINAL 11 of the cruise control ECU. As a result, the cruise control ECU functions and the current flows from the ECU-IG fuse to TERMINAL 9 of the cruise control ECU to TERMINAL 16 of the cruise control ECU to GROUND, and the cruise control system is in a condition ready for operation. At the same time, the current through the GAUGE fuse flows to TERMINAL 9 of the integration relay to TERMINAL (A) 9 to TERMINAL (D) 2 of the cruise control indicator light to TERMINAL (A) 7 to TERMINAL 4 of the cruise control ECU to TERMINAL 16 to GROUND, causing the cruise control indicator light to light up, see Fig. 3 , indicating that cruise control is ready for operation. 1. Set Operation - When the cruise control main SW, see Fig. 2 , is pushed with the vehicle speed within the set limit (Approx. 25 mph. (40 km/h) to 124 mph (200 km/h), a signal is input to terminal

2002 ACCESSORIES & EQUIPMENT Cruise Control Systems - Corolla

10 of the cruise control ECU and the vehicle speed at the time the set SW is released is memorized in the ECU as the set speed. 2. Set Speed Control - During cruise control driving, the ECU compares the set speed memorized in the ECU with the actual vehicle speed input into TERMINAL 12 of the cruise control ECU from the speed sensor via combination meter, and controls the cruise control actuator to maintain the set speed. When the actual speed is lower than the set sped, the ECU causes the current to the cruise control actuator to flow from TERMINAL 15 of the cruise control ECU to TERMINAL 1 of the cruise control actuator to TERMINAL 2 to TERMINAL 7 of the cruise control ECU. As a result, the motor in the cruise control actuator is rotated to open the throttle valve and the throttle cable is pulled to increase the vehicle speed. When the actual driving speed is higher than the set speed, the current to the cruise control actuator flows from TERMINAL 7 of the ECU to TERMINAL 2 of the cruise control actuator to TERMINAL 1 to TERMINAL 15 of the cruise control ECU. This causes the motor in the cruise control actuator to rotate to close the throttle valve and return the throttle cable to decrease the vehicle speed. 3. Coast Control - During cruise control driving, while the COAST SW is on, see Fig. 4 , the cruise control actuator returns the throttle cable to close the throttle valve and decrease the driving speed. The vehicle speed when the coast SW is turned off is memorized and the vehicle continues at the new set speed. 4. Accel Control - During cruise control driving, while the ACCEL SW is turned on, the cruise control actuator pulls the throttle cable to open the throttle valve and increase the driving speed. The vehicle speed when the ACCEL SW is turned off is memorized and the vehicle continues at the new set speed. 5. Resume Control - Unless the vehicle falls below the minimum speed limit (Approximately 25 mph. (40 km/h.)) after cancelling the set speed by the cancel SW, pushing the resume SW, see Fig. 5 , pushing the resume SW will cause the vehicle to resume the speed set before cancellation. 6. Manual Cancelling Mechanism - If any of the following operations occurs during cruise control operation, the magnetic clutch of the actuator turns off and the motor rotates to close the throttle valve and the cruise control is released. Placing the shift lever to positions except "D" position (Park/Neutral position SW except "D" position)(A/T), Depressing the clutch pedal (Cruise control clutch SW off)(M/T). "Signal is not input to TERMINAL 3 of the ECU". Depressing the brake pedal (Stop light SW on). Signal input to TERMINAL 2 of the ECU". Pushing the cancel SW (Cancel SW on). "Signal input to TERMINAL 10 of the ECU". Pushing the CRUISE SW off "signal input to TERMINAL 11 of the ECU". 7. Tap-Up Control Function - When the difference between the actual vehicle speed and the set speed is less than 3 mph (5 km/h), the set speed can be increased 1.0 mph (1.6 km/h.) each time by operating the RESUME/ACCEL SW quickly within 0.6 seconds. See Fig. 5 . 8. Tap-Down Control Function - When the difference between the actual vehicle speed and the set speed is less than 3 mph (5 km/h), the set speed can be lowered 1.0 mph (1.6 km/h.) each time by operating the SET/COAST SW quickly within 0.6 seconds. 9. Auto Cancel Function A. If any of the following operating conditions occurs during cruise control operation, the set speed is erased, current flow to the magnetic clutch is stopped and the cruise control is released.

2002 ACCESSORIES & EQUIPMENT Cruise Control Systems - Corolla

(CRUISE SW turns off). When this occurs, the ignition SW must be turned off once before the main CRUISE SW will turn on. When current continued to flow to the motor inside the actuator in the throttle valve "OPEN" direction. The motor does not operate despite the motor drive signal being output. B. If any of the following operating conditions occurs during cruise control operation, the set speed is erased, the current flow to the magnetic clutch is stopped and the cruise control is released. (CRUISE SW turn off). When this occurs, the cancel state is cleared as the CRUISE SW will turn on again. Over current to transistor driving the motor and/or the magnetic clutch. Open circuit in the magnetic clutch. Momentary interruption of vehicle speed signal. Short circuit in the cruise control switch. C. If any of the following conditions occurs during cruise control operation, the set speed is erased and the cruise control is released. (The power to the magnetic clutch is cut off until the SET SW is "ON" again.) When the vehicle speed falls below the minimum speed limit, approx. 25 mph (40 km/h). When power to the cruise control system is momentarily cut off. 10. Automatic Transaxle Control Function In overdrive. If the vehicle speed becomes lower than the overdrive cut speed (set speed minus approx. 2.5 mph (4 km/h.)) during cruise control operation, such as driving up a hill, the overdrive is released and the power increased to prevent a reduction in vehicle speed. After releasing the overdrive, if the vehicle speed becomes higher than the overdrive return speed (Set speed minus approx. 1.2 mph. (2 km/h)) and the ECU judges by the signals from the actuators potentiometer that the upward slope has finished, the overdrive is resumed after approximately 2 seconds. During cruise control driving, the cruise control operation signal is output from the cruise control ECU to the engine control module. Upon receiving this signal, the engine control module changes the shift pattern to normal.

To maintain smooth cruise control operation (on a downward slope etc.), the lock-up release to the transaxle when the idling point of the throttle position is "ON" is forbidden.

2002 ACCESSORIES & EQUIPMENT Cruise Control Systems - Corolla

Fig. 1: Identifying ECU Terminals & Voltages Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 ACCESSORIES & EQUIPMENT Cruise Control Systems - Corolla

Fig. 2: Identifying Cruise Control On & Off Button (Main Switch) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 ACCESSORIES & EQUIPMENT Cruise Control Systems - Corolla

Fig. 3: Locating Instrument Panel Cruise Control Indicator Lamp Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 ACCESSORIES & EQUIPMENT Cruise Control Systems - Corolla

Fig. 4: Identifying Set/Coast Setting Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 ACCESSORIES & EQUIPMENT Cruise Control Systems - Corolla

Fig. 5: Identifying Res/Acc Setting Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

OPERATION
WARNING:

To avoid accidental cruise control engagement, keep the cruise control on-off switch, see Fig. 2 , off when not using the cruise control. To help maintain maximum control of your vehicle, do not use the cruise control when driving in heavy traffic, or on slippery (rainy, icy or snow-covered) or winding roads. Avoid vehicle speed increases when driving downhill. If the vehicle speed is too fast in relation to the cruise control then downshift the transmission to use engine braking to slow down.

2002 ACCESSORIES & EQUIPMENT Cruise Control Systems - Corolla

CAUTION: For manual transmission: While driving with the cruise control on, do not shift to neutral without depressing the clutch pedal, as this may cause engine racing or overrevving. The cruise control allows you to cruise the vehicle at a desired speed over 25 mph (40 km/h) even with your foot off the accelerator pedal. Your cruising speed can be maintained up or down grades within the limits of engine performance, although a slight speed change may occur when driving up or down the grades. On steeper hills, a greater speed change will occur so it is better to drive without the cruise control. CRUISE CONTROL SWITCH
ON/OFF Button

Turning On The System - To operate the cruise control, press the "CRUISE ON-OFF " button. See Fig. 2 . This turns the system on. The indicator light in the instrument panel shows that you can now set the vehicle at a desired cruising speed. See Fig. 3 . Another press will turn the system completely off.
SET/COAST Switch

Setting A Desired Speed - On vehicles with automatic transmission, the transmission must be in "D" before you set the cruise control speed. Bring your vehicle to the desired speed, push the lever down in the "SET/COAST " direction and release it. See Fig. 4 . This sets the vehicle at that speed. If the speed is not satisfactory, tap it down for a lower speed. Each tap changes the set speed by 1.0 mph (1.6 km/h.). You can now take your foot off the accelerator pedal. Resetting To A Slower Speed - Push the lever down in the "SET/COAST " direction and hold it. See Fig. 4 . Release the lever when the desired speed is attained. while the lever is held down, the vehicle speed will gradually decrease. However a faster way to reset is to depress the brake pedal and then push the lever down in the "SET/COAST " direction. On vehicles with 4-speed transmissions, even if you turn off the overdrive switch, with the cruise control on, engine braking will not be applied because the cruise control in not cancelled. To decrease the vehicle speed, reset to a slower speed with the cruise control lever or depress the rake pedal. If you use the brake pedal, cruise control is cancelled.
RES/ACC Switch

Resetting To A Faster Speed - Push the lever up in the "RES/ACC" direction and hold it. See Fig. 5 . Release the lever when the desired speed is attained. while the lever is held up, the vehicle will gradually gain speed. However, a faster way to reset is to accelerate the vehicle then push the lever down in the "SET/COAST" direction. Resuming The Preset Speed - If the preset speed is cancelled by pulling the control lever or by depressing

2002 ACCESSORIES & EQUIPMENT Cruise Control Systems - Corolla

the brake pedal or clutch pedal, pushing the lever up in the "RES/ACC" direction will restore the speed set prior to cancellation. See Fig. 5 . However, once the vehicle speed falls below about 25 mph (40 km/h), the preset speed will not be resumed.
CANCEL Switch

Canceling The Preset Speed - See MANUAL CANCELLING MECHANISM and AUTO CANCEL FUNCTION under DESCRIPTION.
Cruise Control Failure Warning

NOTE:

A blinking indicator light indicates a trouble code display, and counting blinks in between long pauses derives the DTC number. See Fig. 6 .

If the cruise control light in the instrument panel flashes, see Fig. 3 , when using the cruise control, press the "CRUISE ON-OFF" button, see Fig. 2 , to turn the system off and then press it again to turn it on. If any of the following conditions then occurs, there is some trouble in the cruise control system.

The indicator light does not come on. The indicator light flashes again. The indicator light goes out after it comes on.

2002 ACCESSORIES & EQUIPMENT Cruise Control Systems - Corolla

Fig. 6: Reading DTCs Output By Flashes Of Cruise Indicator Light Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

COMPONENT LOCATIONS
NOTE: For additional cruise control system component locations, see Fig. 7 . For

2002 ACCESSORIES & EQUIPMENT Cruise Control Systems - Corolla

connectors, grounding points, splices and other electrical components, see ELECTRICAL COMPONENT LOCATOR article in ELECTRICAL.

Fig. 7: Locating Cruise Control Components Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

ADJUSTMENTS
NOTE: Engine Control Module (ECM) monitors and commands throttle control system electronically.

2002 ACCESSORIES & EQUIPMENT Cruise Control Systems - Corolla

TROUBLE SHOOTING
NOTE: Customer Problem Analysis - Use the Customer Problem Analysis (Cruise Control System Check List) in conjunction with the trouble shooting flow chart. See Fig. 9 and Fig. 10 .

PRE-CHECK 1. Diagnose System : NOTE: If the indicator check result is not normal, proceed to trouble shooting for the combination meter section. See Troubleshooting - Combination Meter (Warning Lights).

a. Check the indicator: 1. Turn the ignition switch ON. 2. Check that the CRUISE main indicator light comes ON when the cruise control main switch is turned ON, and that the indicator light goes off when the main switch is turned OFF. See Fig. 3 . NOTE: If a malfunction occurs in the No. 1 vehicle speed sensor or actuator, etc. during cruise control driving, the ECU actuates AUTO CANCEL of the cruise control and turns on and off the CRUISE MAIN indicator light to inform the driver of a malfunction. See Fig. 8 . At the same time, the malfunction is stored in memory as a DTC.

b. Check the DTC: NOTE: If The DTC is not output, inspect the diagnosis circuit. See DIAGNOSTICS - CRUISE CONTROL SYSTEM. As an example, the blinking patterns for codes; normal, 11 and 21 are shown in the illustration. See Fig. 6 .

c. Output a DTC using diagnosis check wire: 1. Turn the ignition switch ON. 2. Using SST, connect terminals Tc and E1 of the DLC1. See Fig. 12 . SST 09843-18020. 3. Read the DTC on the CRUISE MAIN indicator light. See Fig. 3 . 2. ECU Terminal Values Measurement By Using Toyota Break-Out-Box And Toyota Hand-Held Tester See Fig. 11 a. Connect the TOYOTA break-out-box and TOYOTA hand-held tester to the vehicle. b. Read the ECU input/output values by following the prompts on the tester screen. c. TOYOTA hand-held tester has a "Snapshot" function. This records the measured valves and is effective in the diagnosis of intermittent problems. Please refer to the TOYOTA hand-held tester/TOYOTA break-out-box operator's manual for further details.

2002 ACCESSORIES & EQUIPMENT Cruise Control Systems - Corolla

NOTE:

TOYOTA hand-held tester has a "Snapshot" function which re- cords the monitored data. Please refer to the TOYOTA hand-held tester operator's manual for further details.

3. Using Toyota Hand-Held Tester : a. Connect the TOYOTA hand-held tester to the DLC1. b. Monitor the ECU data by following the prompts on the tester screen. NOTE: During in the erase mode, diag detection does not work.

4. Erase Mode (DTC Clearance) : a. Drive at about 15 km/h or below. b. Using SST, connect terminals Tc and E1 of DLC1. See Fig. 13 . SST 09843-18020. c. Pull the cruise control switch to CANCEL. d. On the above mentioned condition, turn on the cruise control main switch 5, times within 3 seconds. 5. Road Test: Problem Symptom Confirmation : a. Inspect the SET switch, see Fig. 2 : 1. Push the main switch ON. See Fig. 2 . 2. Drive at a desired speed (25 mph (40 km/h). or higher). 3. Press the control switch to the SET/COAST. See Fig. 4 . 4. After releasing the switch, check that the vehicle cruises at the desired speed. b. Inspect the ACCEL switch: 1. Push the main switch ON. See Fig. 2 . 2. Drive at a desired speed (25 mph (40 km/h). or higher). 3. Check that the vehicle speed increases while the control switch is turned to RES/ACC, and that the vehicle cruises at the set speed when the switch is released. See Fig. 5 . 4. Momentarily raise the control switch upward for RES/ACC and then immediately release it. Check that the vehicle speed increases by about 1.5 Km/h (Tap-up function). c. Inspect the COAST switch: 1. Push the main switch ON. See Fig. 2 . 2. Drive at a desired speed 25 mph (40 km/h) or higher. 3. Check that the vehicle speed decreases while the control switch is turned to SET/COAST, and the vehicle cruises at the set speed when the switch is released. See Fig. 4 . 4. Momentarily push the control switch downward for SET/COAST, and then immediately release it. Check that the vehicle speed decreases by about 1.5 km/h (Tap-down function). d. Inspect the CANCEL switch: 1. Push the main switch ON. See Fig. 2 . 2. Drive at a desired speed 25 mph (40 km/h) or higher. 3. When operating one of the followings, check that the cruise control system is cancelled and that the normal driving mode is reset.

2002 ACCESSORIES & EQUIPMENT Cruise Control Systems - Corolla

. Depress the brake pedal. . Depress the clutch pedal (M/T). . Shift to except "D" position (A/T). . Push the main switch OFF. . Pull the cruise control switch for CANCEL. e. Inspect the RESUME switch: 1. Push the main switch ON. See Fig. 2 . 2. Drive at a desired speed 25 mph (40 km/h) or higher. 3. When operating one of the following operations, check that the cruise control system is cancelled and that the normal driving mode is reset: . Depress the brake pedal. . Depress the clutch pedal (M/T). . Shift to except "D" position (A/T). 4. After the control switch is turned to RES/ACC at the driving speed of more than 25 mph (40 km/h), check that the vehicle restores the speed prior to the cancellation. NOTE: When 2 or more signals are input to the ECU, the lowest numbered code will be displayed 1 st. For check No. 1- 3, Turn ignition switch ON. For check No.4 Jack up the vehicle, Start the engine, Shift to D position. 6. Input Signal Check . See Fig. 15 . a. Press the control switch to SET/COAST or RES/ACC position and hold it down or hold it up as "1". b. Push the main switch ON as "2". c. Check that the CRUISE MAIN indicator light blinks twice or 3 times repeatedly after 3 seconds. d. Turn the SET/COAST or RES/ACC switch OFF. e. Operate each switch as listed in the table below. f. Read the blinking pattern of the CRUISE MAIN indicator light. g. After performing the check, turn the main switch OFF. Problem Symptoms Table Symptom Suspect Area SET not occurring or CANCEL occurring. (DTC is Normal) ..... Main Switch Circuit (Cruise control switch)

See
(1)

2002 ACCESSORIES & EQUIPMENT Cruise Control Systems - Corolla

..... ..... ..... ..... ..... ..... ..... .....

Vehicle Speed Sensor Control Switch Circuit (Cruise control switch) Stop Light Switch Circuit Park/Neutral Position Switch Circuit Clutch Switch Actuator Motor Circuit Cruise Control Cable Cruise Control ECU

(2) (3) (4) (5) (6) (7) (8) (9) (10) (9) (8) (11) (12) (7) (13) (9) (12) (9) (8) (4) (7) (9) (8) (5) (7) (9) (8) (6) (7) (9)

SET not occurring or CANCEL occurring. (DTC dose not output) ..... ECU Power Source Circuit ..... Cruise Control ECU Actual vehicle speed deviates above or below the set speed. ..... Cruise Control Cable ..... ..... ..... ..... ..... Vehicle Speed Signal Abnormal Electronically Controlled Transmission Communication Circuit Actuator Motor Circuit Idle Signal Circuit (Main throttle position sensor) Cruise Control ECU

Gear shifting frequent between 3rd & O/D when driving on uphill road. (Hunting). ..... Electronically Controlled Transmission Communication Circuit ..... Cruise Control ECU Cruise control not cancelled, even when brake pedal is depressed. ..... Cruise Control Cable ..... ..... ..... Stop Light Switch Circuit Actuator Motor Circuit Cruise Control ECU

Cruise control not cancelled, even when transmission is shifted to "N" position. ..... Cruise Control Cable ..... ..... ..... Park/Neutral Position Switch Circuit Actuator Motor Circuit Cruise Control ECU

Cruise control not cancelled, even when clutch pedal is depressed. ..... Cruise Control Cable ..... ..... ..... Clutch Switch Circuit Actuator Motor Circuit Cruise Control ECU

Control switch does not operate. (SET/COAST, ACC/RES, CANCEL impossible)

2002 ACCESSORIES & EQUIPMENT Cruise Control Systems - Corolla

..... ..... ..... .....

Cruise Control Cable Control Switch Circuit Actuator Motor Circuit Cruise Control ECU

(8) (3) (7) (9) (8) (11) (7) (9) (8) (12) (7) (9) (12) (9) (9) (14) (9) (15)

SET possible at 25 mph or less, or CANCEL does not operate at 25 mph or less. ..... Cruise Control Cable ..... ..... ..... Vehicle Speed Signal Abnormal Actuator Motor Circuit Cruise Control ECU

Poor response is in ACCEL and RESUME modes. ..... Cruise Control Cable ..... ..... ..... Electronically Controlled Transmission Communication Circuit Actuator Motor Circuit Cruise Control ECU

O/D does not resume, even though the road is not uphill. ..... Electronically Controlled Transmission Communication Circuit ..... Cruise Control ECU DTC memory is erased. ..... Cruise Control ECU

DTC is not output, or is output when should not be ..... Diagnosis Circuit ..... Cruise Control ECU Cruise MAIN indicator light remains ON or falls to light up ..... Cruise MAIN Indicator Light Switch Circuit
(1) Main Switch Circuit (Cruise Control Switch) (2) DTC 21: OPEN IN VEHICLE SPEED SENSOR CIRCUIT (3) DTC 32: CONTROL SWITCH CIRCUIT (CRUISE CONTROL SWITCH) (4) Stop Light Switch Circuit (5) Park/Neutral Position Switch Circuit (6) Clutch Switch Circuit (7) DTCs 11 & 15: ACTUATOR MOTOR CIRCUIT (8) Actuator Control Cable (9) See How To Troubleshoot ECU Controlled Systems (10) ECU Power Source Circuit (11) DTC 23: VEHICLE SPEED SENSOR ABNORMAL

2002 ACCESSORIES & EQUIPMENT Cruise Control Systems - Corolla

(12) Electronically Controlled Transmission Communication Circuit (13) DTC 51: IDLE SIGNAL CIRCUIT (14) Diagnosis Circuit (15) CRUISE MAIN INDICATOR LIGHT

Fig. 8: Checking Indicator Light DTC Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 ACCESSORIES & EQUIPMENT Cruise Control Systems - Corolla

Fig. 9: Customer Problem Analysis (Cruise Control System Check List) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 ACCESSORIES & EQUIPMENT Cruise Control Systems - Corolla

Fig. 10: Trouble Shooting Flow Chart Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 ACCESSORIES & EQUIPMENT Cruise Control Systems - Corolla

Fig. 11: Connecting Toyota Hand Held Tester Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 ACCESSORIES & EQUIPMENT Cruise Control Systems - Corolla

Fig. 12: Identifying DLC1 Terminals Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 ACCESSORIES & EQUIPMENT Cruise Control Systems - Corolla

Fig. 13: Identifying DTC Clearance Procedure Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 14: Diagnostic Trouble Code Chart Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 ACCESSORIES & EQUIPMENT Cruise Control Systems - Corolla

Fig. 15: Input Signal Chart Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

DIAGNOSTIC TESTS
NOTE: To identify cruise control connector terminals and wire colors, see CRUISE CONTROL in SYSTEM WIRING DIAGRAMS article in ELECTRICAL.

DTCS 11 & 15: ACTUATOR MOTOR CIRCUIT For DTCs 11 and 15 diagnosis, see Fig. 16 and Fig. 17 .

2002 ACCESSORIES & EQUIPMENT Cruise Control Systems - Corolla

Fig. 16: Diagnosing DTCs 11 & 15 (1 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 ACCESSORIES & EQUIPMENT Cruise Control Systems - Corolla

Fig. 17: Diagnosing DTCs 11 & 15 (2 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. DTC 12: ACTUATOR MAGNETIC CLUTCH CIRCUIT For DTC 12 diagnosis, see Fig. 18 -Fig. 20 .

2002 ACCESSORIES & EQUIPMENT Cruise Control Systems - Corolla

Fig. 18: Diagnosing DTC 12 (1 Of 3) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 ACCESSORIES & EQUIPMENT Cruise Control Systems - Corolla

Fig. 19: Diagnosing DTC 12 (2 Of 3) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 ACCESSORIES & EQUIPMENT Cruise Control Systems - Corolla

Fig. 20: Diagnosing DTC 12 (3 Of 3) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. DTC 14: ACTUATOR MECHANICAL MALFUNCTION For DTC 14 diagnosis, see Fig. 21 and Fig. 22 .

2002 ACCESSORIES & EQUIPMENT Cruise Control Systems - Corolla

Fig. 21: Diagnosing DTC 14 (1 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 ACCESSORIES & EQUIPMENT Cruise Control Systems - Corolla

Fig. 22: Diagnosing DTC 14 (2 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. DTC 21: OPEN IN VEHICLE SPEED SENSOR CIRCUIT For DTC 21 diagnosis, see Fig. 23 and Fig. 24 .

2002 ACCESSORIES & EQUIPMENT Cruise Control Systems - Corolla

Fig. 23: Diagnosing DTC 21 (1 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 ACCESSORIES & EQUIPMENT Cruise Control Systems - Corolla

Fig. 24: Diagnosing DTC 21 (2 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. DTC 23: VEHICLE SPEED SENSOR ABNORMAL For DTC 23 diagnosis, see Fig. 25 .

2002 ACCESSORIES & EQUIPMENT Cruise Control Systems - Corolla

Fig. 25: Diagnosing DTC 23 Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. DTC 32: CONTROL SWITCH CIRCUIT (CRUISE CONTROL SWITCH) For DTC 32 diagnosis, see Fig. 26 -Fig. 28 .

2002 ACCESSORIES & EQUIPMENT Cruise Control Systems - Corolla

Fig. 26: Diagnosing DTC 32 (1 Of 3) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 ACCESSORIES & EQUIPMENT Cruise Control Systems - Corolla

Fig. 27: Diagnosing DTC 32 (2 Of 3) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 ACCESSORIES & EQUIPMENT Cruise Control Systems - Corolla

Fig. 28: Diagnosing DTC 32 (3 Of 3) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. DTC 51: IDLE SIGNAL CIRCUIT For DTC 51 diagnosis, see Fig. 29 -Fig. 31 .

2002 ACCESSORIES & EQUIPMENT Cruise Control Systems - Corolla

Fig. 29: Diagnosing DTC 51 (1 Of 3) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 ACCESSORIES & EQUIPMENT Cruise Control Systems - Corolla

Fig. 30: Diagnosing DTC 51 (2 Of 3) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 ACCESSORIES & EQUIPMENT Cruise Control Systems - Corolla

Fig. 31: Diagnosing DTC 51 (3 Of 3) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

SYSTEM TESTS
ACTUATOR CONTROL CABLE For Actuator control cable testing procedure, see Fig. 32 .

2002 ACCESSORIES & EQUIPMENT Cruise Control Systems - Corolla

Fig. 32: Testing Actuator Control Cable Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. CLUTCH SWITCH CIRCUIT For Clutch switch circuit testing procedure, see Fig. 33 and Fig. 34 .

2002 ACCESSORIES & EQUIPMENT Cruise Control Systems - Corolla

Fig. 33: Testing Clutch Switch Circuit (1 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 ACCESSORIES & EQUIPMENT Cruise Control Systems - Corolla

Fig. 34: Testing Clutch Switch Circuit (2 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. CRUISE MAIN INDICATOR LIGHT For cruise main indicator light testing procedure, see Fig. 35 and Fig. 36 .

2002 ACCESSORIES & EQUIPMENT Cruise Control Systems - Corolla

Fig. 35: Testing Cruise Main Indicator Light (1 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 ACCESSORIES & EQUIPMENT Cruise Control Systems - Corolla

Fig. 36: Testing Cruise Main Indicator Light (2 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. DIAGNOSIS CIRCUIT For diagnosis circuit testing procedure, see Fig. 37 and Fig. 38 .

2002 ACCESSORIES & EQUIPMENT Cruise Control Systems - Corolla

Fig. 37: Testing Diagnosis Circuit (1 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 ACCESSORIES & EQUIPMENT Cruise Control Systems - Corolla

Fig. 38: Testing Diagnosis Circuit (2 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ECU POWER SOURCE CIRCUIT For ECU power source circuit testing procedure, see Fig. 39 and Fig. 40 .

Fig. 39: Testing ECU Power Source Circuit (1 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 ACCESSORIES & EQUIPMENT Cruise Control Systems - Corolla

Fig. 40: Testing ECU Power Source Circuit (2 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ELECTRONICALLY CONTROLLED TRANSMISSION COMMUNICATION CIRCUIT For electronically controlled transmission communication circuit testing procedures, see Fig. 41 -Fig. 43 .

2002 ACCESSORIES & EQUIPMENT Cruise Control Systems - Corolla

Fig. 41: Testing Electronically Controlled Transmission Communication Circuit (1 Of 3) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 ACCESSORIES & EQUIPMENT Cruise Control Systems - Corolla

Fig. 42: Testing Electronically Controlled Transmission Communication Circuit (2 Of 3) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 ACCESSORIES & EQUIPMENT Cruise Control Systems - Corolla

Fig. 43: Testing Electronically Controlled Transmission Communication Circuit (3 Of 3) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. MAIN SWITCH CIRCUIT (CRUISE CONTROL SWITCH) For Main switch circuit testing procedure, see Fig. 44 and Fig. 45 .

2002 ACCESSORIES & EQUIPMENT Cruise Control Systems - Corolla

Fig. 44: Testing Main Switch Circuit (1 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 ACCESSORIES & EQUIPMENT Cruise Control Systems - Corolla

Fig. 45: Testing Main Switch Circuit (2 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. PARK/NEUTRAL POSITION SWITCH CIRCUIT For Park/Neutral Position Switch Circuit testing procedure, see Fig. 46 -Fig. 48 .

2002 ACCESSORIES & EQUIPMENT Cruise Control Systems - Corolla

Fig. 46: Testing Park/Neutral Position Switch Circuit (1 Of 3) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 ACCESSORIES & EQUIPMENT Cruise Control Systems - Corolla

Fig. 47: Testing Park/Neutral Position Switch Circuit (2 Of 3) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 ACCESSORIES & EQUIPMENT Cruise Control Systems - Corolla

Fig. 48: Testing Park/Neutral Position Switch Circuit (3 Of 3) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. STOP LIGHT SWITCH CIRCUIT For Stop light switch circuit testing procedure, see Fig. 49 -Fig. 51 .

2002 ACCESSORIES & EQUIPMENT Cruise Control Systems - Corolla

Fig. 49: Testing Stop Light Switch Circuit (1 Of 3) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 ACCESSORIES & EQUIPMENT Cruise Control Systems - Corolla

Fig. 50: Testing Stop Light Switch Circuit (2 Of 3) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 ACCESSORIES & EQUIPMENT Cruise Control Systems - Corolla

Fig. 51: Testing Stop Light Switch Circuit (3 Of 3) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

WIRING DIAGRAMS
NOTE: For wiring diagram, see CRUISE CONTROL in SYSTEM WIRING DIAGRAMS article.

2002 ACCESSORIES & EQUIPMENT Power Door Lock Control System - Corolla

2002 ACCESSORIES & EQUIPMENT Power Door Lock Control System - Corolla

POWER DOOR LOCK CONTROL SYSTEM

NOTE: For manufacturers precautions, see BODY, CAB CONTROL SYSTEMS . For circuit troubleshooting, see POWER DOOR LOCK CONTROL SYSTEM . For circuit wiring diagrams, see POWER DOOR LOCKS .

LOCATION

2002 ACCESSORIES & EQUIPMENT Power Door Lock Control System - Corolla

Fig. 1: Locating Power Door Lock Control System Components Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSPECTION 1. W/Power window, inspect driver's door lock control switch continuity : Master switch:

2002 ACCESSORIES & EQUIPMENT Power Door Lock Control System - Corolla

Fig. 2: Identifying Driver's Door Lock Control Switch Terminals (W/Power Window) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 ACCESSORIES & EQUIPMENT Power Door Lock Control System - Corolla

Fig. 3: Identifying Driver's Door Lock Control Switch Terminal Specifications (W/Power Window) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. If continuity is not as specified, replace the switch. 2. W/Power window, inspect passenger's door lock manual switch continuity :

Fig. 4: Identifying Passenger's Door Lock Manual Switch Terminals (W/Power Window) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 ACCESSORIES & EQUIPMENT Power Door Lock Control System - Corolla

Fig. 5: Passenger's Door Lock Manual Switch Terminal Specifications (W/Power Window) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. If continuity is not as specified, replace the switch. 3. W/O Power window, inspect driver's and passenger's door lock manual switch continuity :

Fig. 6: Identifying Passenger's & Driver's Door Lock Manual Switch Terminals (W/O Power Window) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 ACCESSORIES & EQUIPMENT Power Door Lock Control System - Corolla

Fig. 7: Passenger's Door Lock Manual Switch Terminal Specifications (W/O Power Window) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. If continuity is not as specified, replace the switch. 4. Inspect door key lock and unlock switch continuity :

Fig. 8: Identifying Door Key Lock & Unlock Switch Terminals & Test Positions Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 ACCESSORIES & EQUIPMENT Power Door Lock Control System - Corolla

Fig. 9: Front Left Side Door Key Lock & Unlock Switch Terminal Specifications Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. If continuity is not as specified, replace the switch. 5. Inspect door unlock detection switch continuity :

Fig. 10: Identifying Door Unlock Detection Switch Terminals & Test Positions Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 ACCESSORIES & EQUIPMENT Power Door Lock Control System - Corolla

Fig. 11: Driver's Door Unlock Detection Switch Specifications Chart Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. If continuity is not as specified, replace the switch. 6. Inspect door lock motor operation : a. Connect the positive (+) lead from the battery to terminal 3 and the negative (-) lead to terminal 2, and check that the door lock link moves to UNLOCK position.

Fig. 12: Testing Door Lock Motor

2002 ACCESSORIES & EQUIPMENT Power Door Lock Control System - Corolla

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Reverse the polarity and check that the door lock link moves to LOCK position. If operation is not as specified, replace the door lock assembly. 7. Using an ammeter, inspect door lock motor PTC thermistor operation : a. Connect the negative (-) lead from the battery to terminal 2.

Fig. 13: Testing Door Lock Motor PTC Thermistor Using Ammeter (1 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Connect the positive (+) lead from the ammeter to terminal 3 and the negative (-) lead to battery positive (+) terminal, and check that the current changes from approximately 3.2 A to less than 0.5 A within 20 to 70 seconds. c. Disconnect the leads from terminals.

2002 ACCESSORIES & EQUIPMENT Power Door Lock Control System - Corolla

Fig. 14: Testing Door Lock Motor PTC Thermistor Using Ammeter (1 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. d. Approximately 60 seconds later, connect the positive (+) lead from the battery to terminal 2 and the negative (-) lead to terminal 3, and check that the door lock moves to the LOCK position. If operation is not as specified, replace the door lock assembly. 8. Using an ammeter with a current-measuring probe, inspect door lock motor PTC thermistor operation : a. Connect the positive (+) lead from the battery to terminal 3 and the negative (-) lead to terminal 2.

2002 ACCESSORIES & EQUIPMENT Power Door Lock Control System - Corolla

Fig. 15: Testing Door Lock Motor PTC Thermistor Using Ammeter W/Current Probe (1 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Attach a current-measuring probe to either the positive (+) lead or the negative (-) lead, and check that the current changes from approximately 3.2 A to less than 0.5 A within 20 to 70 seconds. c. Disconnect the leads from terminals. d. Approximately 60 seconds later, reverse the polarity, and check that the door lock moves to the LOCK position.

2002 ACCESSORIES & EQUIPMENT Power Door Lock Control System - Corolla

Fig. 16: Testing Door Lock Motor PTC Thermistor Using Ammeter W/Current Probe (2 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. If operation is not as specified, replace the door lock assembly. 9. Inspect door lock control relay (integration relay) circuit : Disconnect the connector from the integration relay and inspect the connector on the wire harness side, as shown in the chart.

2002 ACCESSORIES & EQUIPMENT Power Door Lock Control System - Corolla

Fig. 17: Identifying Door Lock Control Relay (Integration Relay) Terminals Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 ACCESSORIES & EQUIPMENT Power Door Lock Control System - Corolla

Fig. 18: Door Lock Control Relay (Integration Relay) Terminal Specifications Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. If circuit is as specified, inspect the door lock signal and key-off power window signal. NOTE: When the relay circuit is as specified, inspect the door lock signal.

10. Door lock signal, inspect door lock control relay (integration relay) operation : a. Connect the relay connector. b. Connect the positive (+) lead from the voltmeter to terminal 8 and the negative (-) lead to terminal 7.

2002 ACCESSORIES & EQUIPMENT Power Door Lock Control System - Corolla

Fig. 19: Testing Door Lock Control Relay/Integration Relay (1 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Set the door lock control switch to UNLOCK and check that the voltage rises from 0 V to battery positive voltage for approximately 0.2 seconds. d. Reverse the polarity of the voltmeter leads. e. Set the door lock control switch to LOCK and check that the voltage rises from 0 V to battery positive voltage for approximately 0.2 seconds.

2002 ACCESSORIES & EQUIPMENT Power Door Lock Control System - Corolla

Fig. 20: Testing Door Lock Control Relay/Integration Relay (2 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. If operation is not as specified, replace the relay.

2002 ACCESSORIES & EQUIPMENT Audio System - Corolla

2002 ACCESSORIES & EQUIPMENT Audio System - Corolla

AUDIO SYSTEM
NOTE: For manufacturers precautions, see BODY, CAB CONTROL SYSTEMS . For wiring diagram, see RADIO .

DESCRIPTION 1. Radio wave band : The radio wave bands used in radio broadcasting are as follows:

Fig. 1: Identifying Radio Band Frequencies & Types Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. LF: Low frequency MF: Medium Frequency HF: High Frequency VHF: Very High Frequency 2. Service area : There are great differences in the size of the service area for AM and FM monaural. Sometimes FM stereo broadcasts cannot be received even through AM comes in very clearly. Not only does FM stereo have the smallest service area, but it also picks up static and other types of interference ("noise") easily.

2002 ACCESSORIES & EQUIPMENT Audio System - Corolla

Fig. 2: Identifying Frequency Service Ranges Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE: Besides the problem of static, there are also the problems called "fading", "multipath" and "fade out". These problems are caused not by electrical noise but by the nature of the radio waves themselves.

3. Reception problems : a. Fading Besides electrical interference, AM broadcasts are also susceptible to other types of interference, especially at night. This is because AM radio waves bounce off the ionosphere at night. These radio waves then interfere with the signals from the same transmitter that reach the vehicle's antenna directly. This type of interference is called "fading".

2002 ACCESSORIES & EQUIPMENT Audio System - Corolla

Fig. 3: Identifying Cause Of Fading Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Multipath One type of interference caused by the bouncing of radio waves off of obstructions is called "multipath". Multipath occurs when a signal from the broadcast transmitter antenna bounces off buildings and mountains and interferes with the signal that is received directly.

2002 ACCESSORIES & EQUIPMENT Audio System - Corolla

Fig. 4: Identifying Cause Of Multipathing Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Fade Out Because FM radio waves are of higher frequencies than AM radio waves, they bounce off buildings, mountains, and other obstructions. For this reason, FM signals often seem to gradually disappear or fade away as the vehicle goes behind a building or other obstruction. This is called "fade out".

2002 ACCESSORIES & EQUIPMENT Audio System - Corolla

Fig. 5: Identifying Cause Of Fade Out Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 4. Tape player/head Cleaning, maintenance: a. Raise the cassette door with your finger. b. Next, using a pencil or like object, push in the guide. c. Using a cleaning pen or cotton applicator soaked in cleaner, clean the head surface, pinch rollers and capstans.

2002 ACCESSORIES & EQUIPMENT Audio System - Corolla

Fig. 6: Locating Head, Pinch Rollers & Capstans Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 5. Outline of AVC-LAN : a. What is AVC-LAN? AVC-LAN is the abbreviation, which stands for Audio Visual Communication-Local Area Network. This is a unified standard co-developed by 6 audio manufactures associated with Toyota Motor Corporation. The Unified standard covers signals, such as audio signal, visual signal, signal for switch indication and communication signal. b. Objectives Recently the car audio system has been rapidly developed and functions have been changed drastically. The conventional system has been switched to the multi-media type such as a navigation system. At the same time the level of customers needs to audio system has been heightened. This lies behind this standardization. The concrete objectives are explained below. When products by different manufacturers were combined together, there used to be a case that malfunction occurred such as sound did not come out. This problem has been resolved by standardization of signals. Various types of after market products have been able to add or replace freely. Thanks to the above (2), each manufacturer has become able to concentrate on developing products in their strongest field. This has enabled many types of products

2002 ACCESSORIES & EQUIPMENT Audio System - Corolla

provided inexpensively. Conventionally, a new product developed by a manufacturer could not be used due to a lack of compatibility with other manufacturers products. Thanks to this new standard, users can enjoy compatible products provided for them timely. The above descriptions are the objectives to introduce AVC-LAN. By this standardization, development of new products will no longer cause systematic errors. Thus, this is a very effective standard for a product in the future.

NOTE:

When +B short or GND short is detected in AVC-LAN circuit, communication stops. Accordingly the audio system does not function normally. When audio system is not equipped with a navigation system, audio head unit is the master unit. The car audio system using AVC-LAN circuit has a diagnosis function. Each product has its own specified numbers called physical address. Numbers are also allotted to each function in one product, which are called logical address.

TROUBLESHOOTING CAUTION: When replacing the internal mechanism (computer part) of the audio system, be careful that no part of your body or clothing comes in contact with the terminals of the leads from the IC, etc. of the replacement part (spare part). NOTE: This inspection procedure is a simple troubleshooting which should be carried out on the vehicle during system operation and was prepared on the assumption of system component troubles (except for the wires and connectors, etc.).

Always inspect the trouble taking the following items into consideration:

Open or short circuit of the wire harness. Connector or terminal connection fault. Component/Description Of Problem/Troubleshooting Isolation Table Component/Problem See Radio Radio Not 1 Operating When Power Switch Turned To "ON" Display Indicates 2 When Power Switch Turned To

2002 ACCESSORIES & EQUIPMENT Audio System - Corolla

"ON," But No Sound (Including 'noise') Is Produced Noise Present, But AM-FM Not Operating Either Speaker Does Not Work Either AM Or FM Does Not Work Reception Poor Few Preset Turning Bands Sound Quality Poor Preset Memory Disappears Cannot Set Station Select Button, Preset Memory Disappears Tape Player Cassette Tape Cannot Be Inserted Cassette Tape Inserts, But No Power Power Coming In, But Tape Player Not Operating Either Speaker Does Not Work Sound Quality Poor Tape Jammed, Malfunction With Tape Speed Or Auto-Reverse Cassette Tape Will Not Eject. Antenna Antenna-Related Noise Noise Occurs Noise Produced By Vibration Or

4 5 5 5 6 7 7

10

11 12 13

14

15 16 17

2002 ACCESSORIES & EQUIPMENT Audio System - Corolla

Shock While Driving Noise Produced When Engine Starts

18

The term "AM" includes LW,MW and SW, and the term "FW" includes UKW 1. Diagnosis function : Error codes over tuner and connected equipment are displayed on the screen of tuner. a. Diagnosis start-up For shifting to diagnosis mode, push "CD" button 3 times with pressing "1" and "6" of TRUCK TUNE APS button at the same time while the audio power is OFF and ACC is ON.

Fig. 7: Locating No. 1, 6, CD & Tune Up/Down Buttons Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. In diagnosis mode, by pressing "CD" button for 2 seconds or turning the ignition key OFF, the diagnosis mode is released. b. LAN check : When starting up the diagnosis mode, the mode turns to LAN check mode, the screen displays the code numbers (physical address) of tuner and connected equipment. Smaller codes are displayed in order, displayed code numbers are switched by operating TUNE "UP" or TUNE "DOWN" button. In LAN check mode, by pressing "5" of TRUCK TUNE APS button for more than 2 secs., diagnosis memory of each equipment can be deleted, when deletion is completed, the mode returns to LAN check mode.

2002 ACCESSORIES & EQUIPMENT Audio System - Corolla

Fig. 8: Code Number/Physical Address Chart Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. System check: When pressing "1" of TRUCK TUNE APS button in LAN check mode, the mode turns to the system check mode, the system performs self diagnosis of connected equipment and displays the results. The smaller code numbers (physical address) are displayed in order (code No. (physical address), diagnosis code, support code of diagnosis code (object equipment)). When no error is detected in the system, "00" is displayed. When an error code is detected, up to 6 codes per one system are displayed. Pressing TUNE "UP" or TUNE "DOWN" switches the display. In the system check mode, when pressing "6" of TRUCK TUNE APS button the mode returns to LAN check mode. d. Diagnosis memory: In LAN check mode, when pressing "2" of TRUCK TUNE APS button the mode turns to the diagnosis memory mode. The results of self diagnosis performed over tuner and connected equipment are memorized and displayed. The smaller code numbers (physical address) are displayed in order (code No. (physical address), periodic communication number when error occurs, diagnosis code, and support code of diagnosis code (object equipment)). When no error is detected in the system, "00" is displayed. When an error code is detected, up to 6 codes per one system are displayed. Pressing TUNE "UP" or TUNE "DOWN" switches the display. Each diagnosis code is same as code in the system check mode. When pressing "6" of TRUCK TUNE APS button, the mode returns to LAN check mode. 2. Diagnosis code list :

2002 ACCESSORIES & EQUIPMENT Audio System - Corolla

Fig. 9: Diagnostic Trouble Code Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 1. Radio not operating when power switch turned to "ON" :

2002 ACCESSORIES & EQUIPMENT Audio System - Corolla

Fig. 10: Not Operating When Power Switch Turned To "ON" (Radio) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 2. Radio display indicates when power switch turned to "ON", but no sound (including "noise") is produced :

2002 ACCESSORIES & EQUIPMENT Audio System - Corolla

Fig. 11: No Sound Produced (Radio) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 3. Radio noise present, but AM-FM not operating :

Fig. 12: Am-Fm Not Operating (Radio) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 4. Radio either speaker does not work :

2002 ACCESSORIES & EQUIPMENT Audio System - Corolla

Fig. 13: Speakers Not Working (Radio) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 5. Radio either AM or FM does not work, reception poor (volume faint), few preset tuning bands :

2002 ACCESSORIES & EQUIPMENT Audio System - Corolla

Fig. 14: Few Tuning Bands Present (Radio) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 6. Radio sound quality poor :

2002 ACCESSORIES & EQUIPMENT Audio System - Corolla

Fig. 15: Poor Sound Quality (Radio) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 7. Radio cannot set station select button, preset memory disappears :

2002 ACCESSORIES & EQUIPMENT Audio System - Corolla

Fig. 16: Preset Memory Disappears (Radio) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 8. Tape player cassette tape cannot be inserted :

2002 ACCESSORIES & EQUIPMENT Audio System - Corolla

Fig. 17: Cannot Insert Tape (Tape Player) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 9. Tape player cassette tape inserts, but no power :

Fig. 18: No Power W/Tape Inserted (Tape Player) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 10. Tape player power coming in, but tape player not operating :

2002 ACCESSORIES & EQUIPMENT Audio System - Corolla

Fig. 19: Tape Player Not Operating W/Power In (Tape Player) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 11. Tape player either speaker does not work :

Fig. 20: Either Speaker Not Working (Tape Player) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 12. Tape player sound quality poor (volume faint)

2002 ACCESSORIES & EQUIPMENT Audio System - Corolla

Fig. 21: Faint Volume/Poor Sound Quality (Tape Player) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 13. Tape player tape jammed, malfunction with tape speed or auto-reverse :

Fig. 22: Jammed Tape (Tape Player) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 14. Tape player cassette tape will not eject :

2002 ACCESSORIES & EQUIPMENT Audio System - Corolla

Fig. 23: Tape Will Not Be Eject (Tape Player) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 15. Antenna-related :

Fig. 24: Antenna Related Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 16. Noise occurs :

2002 ACCESSORIES & EQUIPMENT Audio System - Corolla

Fig. 25: Noise Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 17. Noise produced by vibration or shock while driving:

2002 ACCESSORIES & EQUIPMENT Audio System - Corolla

Fig. 26: Vibration/Shock Causes Of Noise Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 18. Noise produced when engine starts :

2002 ACCESSORIES & EQUIPMENT Audio System - Corolla

Fig. 27: Engine Starting Causes Noise Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. LOCATION

2002 ACCESSORIES & EQUIPMENT Audio System - Corolla

Fig. 28: Locating Audio System Components Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 ACCESSORIES & EQUIPMENT Clock - Corolla

2002 ACCESSORIES & EQUIPMENT Clock - Corolla

CLOCK
TROUBLESHOOTING NOTE: For manufacturers precautions, see BODY, CAB CONTROL SYSTEMS .

Troubleshoot the clock according to CLOCK TROUBLESHOOTING . CLOCK TROUBLESHOOTING Condition Clock Will Not Operate Clock Loses Or Gains Time +/-1.5 seconds/day .

See PROBLEM NO. 1 PROBLEM NO. 2

Fig. 1: Identifying Clock System Connectors & Terminals Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 1. Problem No. 1 , Clock will not operate: a. Check that the battery positive voltage is 10 - 16 V.

2002 ACCESSORIES & EQUIPMENT Clock - Corolla

Fig. 2: Locating B+ & Gnd Terminals Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. If voltage is not as specified, replace the battery. b. Check that the DOME fuse is not blown. If the fuse is blown, replace the fuse and check for short. NOTE: Inspect the connector on the wire harness side.

Fig. 3: Troubleshooting Flow Chart (Clock Not Running) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Troubleshoot the clock as follows: 2. Problem No. 2 , Clock loses or gains time:

2002 ACCESSORIES & EQUIPMENT Clock - Corolla

a. Check that the battery positive voltage is 10 - 16 V.

Fig. 4: Identifying Clock System Terminals Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. If voltage is not as specified, replace the battery. c. Inspect the error of the clock.

2002 ACCESSORIES & EQUIPMENT Clock - Corolla

Allowable error (per day): +/- 1.5 seconds . If the error exceeds the allowable error, replace the clock. d. Check that the clock adjusting button is sticking in position and has failed to return. If the error exceeds the allowable error, replace the clock. NOTE: Inspect the connector on the wire harness side.

Fig. 5: Troubleshooting Flowchart (Clock Loses OR Gains Time) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. e. Troubleshoot the clock as follows.

2002 ACCESSORIES & EQUIPMENT Combination Meter - Corolla

2002 ACCESSORIES & EQUIPMENT Combination Meter - Corolla

COMBINATION METER
NOTE: For manufacturers precautions, see BODY, CAB CONTROL SYSTEMS . For troubleshooting circuit isolation tables, see COMBINATION METER . For circuit wiring diagrams, see INSTRUMENT CLUSTER .

LOCATION

2002 ACCESSORIES & EQUIPMENT Combination Meter - Corolla

Fig. 1: Locating Combination Meter Components (1 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 ACCESSORIES & EQUIPMENT Combination Meter - Corolla

Fig. 2: Locating Combination Meter Components (2 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. CIRCUIT

2002 ACCESSORIES & EQUIPMENT Combination Meter - Corolla

Fig. 3: Locating Combination Meter Connectors & Identifying Terminals Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 ACCESSORIES & EQUIPMENT Combination Meter - Corolla

Fig. 4: Combination Meter Wiring Diagram & Legend Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSPECTION NOTE: Tire wear and tire over or under inflation will increase the indication

2002 ACCESSORIES & EQUIPMENT Combination Meter - Corolla

error.

Fig. 5: Speedometer Allowable Indication Error Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 1. Inspect speedometer on-vehicle : Using a speedometer tester, inspect the speedometer for allowable indication error and check the operation of the odometer. If error is excessive, replace the speedometer. 2. INSPECT VEHICLE SPEED SENSOR OPERATION a. Connect the positive (+) lead from battery to terminal 1 and negative (-) lead to terminal 2. b. Connect the positive (+) lead from tester to terminal 3 and the negative (-) lead to terminal 2.

2002 ACCESSORIES & EQUIPMENT Combination Meter - Corolla

Fig. 6: Testing Vehicle Speed Sensor Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Rotate the shaft. NOTE: The voltage change should be 4 times for every revolution of the speed sensor shaft.

d. Check that there is voltage change from approx. 0 V to 11 V or more between terminals 2 and 3. If operation is not as specified, replace the sensor. NOTE:

Reversing the connection of the tachometer will damage the transistors and diodes inside. When removing or installing the tachometer, be careful not to drop or subject it to heavy shocks.

2002 ACCESSORIES & EQUIPMENT Combination Meter - Corolla

Fig. 7: Tachometer Allowable Error Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 3. Inspect tachometer on-vehicle : a. Connect a tune-up test tachometer, and start the engine. b. Compare the tester and tachometer indications. DC 13.5 V at 25C (77F) 4. Inspect fuel receiver gauge operation : a. Disconnect the connector from the sender gauge. b. Turn the ignition switch ON, check that the receiver gauge needle indicates EMPTY.

2002 ACCESSORIES & EQUIPMENT Combination Meter - Corolla

Fig. 8: Testing Fuel Receiver Gauge Operation (1 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Connect terminals 1 and 2 on the wire harness side connector through a 3.4 W test bulb.

2002 ACCESSORIES & EQUIPMENT Combination Meter - Corolla

Fig. 9: Testing Fuel Receiver Gauge Operation (2 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE: Because of the silicon oil in the gauge, it will take a short time for needle to stabilize.

d. Turn the ignition switch ON, check that the bulb lights up and the receiver gauge needle moves towards the full side. If operation is not as specified, inspect the receiver gauge resistance. 5. W/Tachometer, inspect fuel receiver gauge resistance : Measure the resistance between terminals.

2002 ACCESSORIES & EQUIPMENT Combination Meter - Corolla

Fig. 10: Locating Fuel Receiver Gauge Terminals (W/Tachometer) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 11: Fuel Receiver Gauge Specifications (W/Tachometer) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. If resistance value is not as specified, replace the receiver gauge, 6. W/O Tachometer, inspect fuel receiver gauge resistance : Measure the resistance between terminals.

2002 ACCESSORIES & EQUIPMENT Combination Meter - Corolla

Fig. 12: Locating Fuel Receiver Gauge Terminals (W/O Tachometer) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 13: Fuel Receiver Gauge Specifications (W/O Tachometer) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. If resistance value is not as specified, replace the receiver gauge. 7. Inspect fuel sender gauge resistance : Measure the resistance between terminals 1 and 2 for each float position.

2002 ACCESSORIES & EQUIPMENT Combination Meter - Corolla

Fig. 14: Measuring Fuel Sender Gauge Resistance Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 15: Fuel Sender Gauge Specifications Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. If resistance value is not as specified, replace the sender gauge. 8. Inspect fuel level warning light : a. Disconnect the connector from the sender gauge. b. Connect terminals 1 and 3 on the wire harness side connector.

2002 ACCESSORIES & EQUIPMENT Combination Meter - Corolla

Fig. 16: Testing Fuel Level Warning Light Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE: If the warning light does not light up, test the bulb or inspect wire harness.

c. Turn the ignition switch ON, check that the warning light lights up. 9. Inspect fuel level warning switch : NOTE: It takes a short time for the bulb to light up.

2002 ACCESSORIES & EQUIPMENT Combination Meter - Corolla

Fig. 17: Testing Fuel Level Warning Switch (1 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. a. Apply battery positive voltage between terminals 1 and 3 through a 3.4 W test bulb, check that the bulb lights up. b. Submerge the switch in fuel, check that the bulb goes out. If operation is not as specified, replace the sender gauge.

2002 ACCESSORIES & EQUIPMENT Combination Meter - Corolla

Fig. 18: Testing Fuel Level Warning Switch (2 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 10. Inspect engine coolant temperature receiver gauge operation : a. Disconnect the connector from the sender gauge. b. Turn the ignition switch ON and check that the receiver gauge needle indicates COOL.

2002 ACCESSORIES & EQUIPMENT Combination Meter - Corolla

Fig. 19: Testing Engine Coolant Temperature Receiver Gauge (1 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Ground terminal on the wire harness side connector through a 3.4 W test bulb.

2002 ACCESSORIES & EQUIPMENT Combination Meter - Corolla

Fig. 20: Testing Engine Coolant Temperature Receiver Gauge (2 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. d. Turn the ignition switch ON, and check that the bulb lights up and the receiver gauge needle moves to the hot side. If operation is as specified, replace the sender gauge. Then recheck the system. If operation is not as specified, measure the receiver gauge resistance. 11. Inspect engine coolant temperature receiver gauge resistance : NOTE: Connect the test leads so that the current from the ohmmeter can flow according to the above order. This circuit includes the diode. If resistance value is not as specified, replace the receiver gauge.

2002 ACCESSORIES & EQUIPMENT Combination Meter - Corolla

Fig. 21: Locating Engine Coolant Temperature Receiver Gauge Terminals Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 ACCESSORIES & EQUIPMENT Combination Meter - Corolla

Fig. 22: Engine Coolant Temperature Receiver Gauge Specifications (A-B, A-C & B-C Terminals) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. a. Measure the resistance between terminals. If resistance value is not as specified, replace the receiver gauge. b. Measure the resistance between terminals.

Fig. 23: Engine Coolant Temperature Receiver Gauge Specifications (A-B Terminals) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 12. Inspect engine coolant temperature sender gauge resistance : Connect the wire harness as shown in the illustration, and adjust the ammeter pointer to indicate "O" using the slide rheostat, then read the rheostat indication.

2002 ACCESSORIES & EQUIPMENT Combination Meter - Corolla

Fig. 24: Measuring Engine Coolant Temperature Sender Gauge Resistance Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 25: Engine Coolant Temperature Sender Gauge Specifications Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. If resistance value is not as specified, replace the gauge. 13. Inspect low oil pressure warning light : a. Disconnect the connector from the warning switch and ground terminal on the wire harness side connector.

2002 ACCESSORIES & EQUIPMENT Combination Meter - Corolla

b. Turn the ignition switch ON and check that the warning light lights up.

Fig. 26: Testing Low Oil Pressure Warning Light Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. If the warning light does not light up, test the bulb. NOTE: Oil pressure should be over 24.5 kPa (0.25 kgf/cm2 , 3.55 psi).

14. Inspect low oil pressure switch continuity : a. Disconnect the connector from the switch. b. Check that there is continuity between terminal and ground with the engine stopped.

2002 ACCESSORIES & EQUIPMENT Combination Meter - Corolla

Fig. 27: Testing Low Oil Pressure Switch Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Check that there is no continuity between terminal and ground with the engine running. If operation is not as specified, replace the switch. 15. Inspect brake warning light : a. Disconnect the connector from the brake fluid warning switch. b. Release the parking brake pedal. c. Connect the terminals on the wire harness side of the level warning switch connector.

2002 ACCESSORIES & EQUIPMENT Combination Meter - Corolla

Fig. 28: Testing Brake Warning Light Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. d. Start the engine, check that the warning light lights up. If the warning light does not light up, test the bulb or wire harness. 16. Inspect brake fluid level warning switch continuity : a. Remove the reservoir tank cap and strainer. b. Disconnect the connector. c. Check that there is no continuity between the terminals with the switch OFF (float up).

2002 ACCESSORIES & EQUIPMENT Combination Meter - Corolla

Fig. 29: Testing Brake Fluid Level Warning Switch Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. d. Use siphon, etc. to take fluid out of the reservoir tank. e. Check that there is continuity between the terminals with the switch ON (float down) f. Pour the fluid back in the reservoir tank. If operation is not as specified, replace the switch. 17. Inspect parking brake switch continuity : a. Check that there is continuity between the terminal and switch body with the switch ON (switch pin released).

2002 ACCESSORIES & EQUIPMENT Combination Meter - Corolla

Fig. 30: Testing Parking Brake Switch Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Check that there is no continuity between the terminal and switch body with the switch OFF (switch pin pushed in). If operation is not as specified, replace the switch or inspect ground point. 18. Inspect open door warning light : Disconnect the connector from the door courtesy switch and ground terminal 1 on the wire harness side, and check that the warning light lights up.

2002 ACCESSORIES & EQUIPMENT Combination Meter - Corolla

Fig. 31: Testing Open Door Warning Light Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. If the warning light does not light up, inspect the bulb or wire harness. 19. Inspect door courtesy switch continuity. See INSPECTION . 20. Inspect light control rheostat operation : a. Connect terminals 1 and 3 through a 3.4 W test bulb.

2002 ACCESSORIES & EQUIPMENT Combination Meter - Corolla

Fig. 32: Testing Light Control Rheostat Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Connect the positive (+) lead from the battery to terminal 1 and the negative (-) lead to terminal 2, c. Gradually turn the rheostat knob from the bright side to dark side, and check that the test bulb brightness changes from bright to dark. If operation is not as specified, replace the rheostat light control. 21. Inspect bulb check relay operation : a. Connect the positive (+) lead from the battery to terminal C through a 1.4 W test bulb and the negative (-) lead to terminal B, check that the test bulb does not light up.

2002 ACCESSORIES & EQUIPMENT Combination Meter - Corolla

Fig. 33: Testing Bulb Check Relay Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Connect the positive (+) lead from the battery to terminal A and check that the test bulb lights up. If operation is not as specified, replace the replace the relay. 22. Inspect window washer level warning light : a. Disconnect the connector from the warning switch and ground terminal on the wire harness side connector.

2002 ACCESSORIES & EQUIPMENT Combination Meter - Corolla

Fig. 34: Testing Window Washer Level Warning Light Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Turn the ignition switch ON and check that the warning light lights up. If the warning light does not light up, inspect the bulb or wire harness. 23. Inspect window washer level warning switch continuity : a. Check that there is no continuity between the terminals with the switch OFF (float up).

2002 ACCESSORIES & EQUIPMENT Combination Meter - Corolla

Fig. 35: Testing Window Washer Level Warning Switch Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Check that there is continuity between the terminals with the switch ON (float down) If operation is not as specified, replace the switch or inspect ground point. 24. Inspect seat belt warning light a. Disconnect the connector from the retractor switch and ground terminal on the wire harness side connector.

2002 ACCESSORIES & EQUIPMENT Combination Meter - Corolla

Fig. 36: Testing Seat Belt Warning Light Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Turn the ignition switch ON and check that the warning light lights up. If the warning light does not light up, inspect the bulb or wire harness. 25. Inspect buckle switch continuity : 1. Check that continuity exists between terminals 1 and 2 the switch side connectors with the switch OFF (belt fastened).

2002 ACCESSORIES & EQUIPMENT Combination Meter - Corolla

Fig. 37: Testing Buckle Switch Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 2. Check that no continuity exists between terminals 1 and 2 the switch side connectors with the switch ON (belt unfastened). If operation is not as specified, replace the switch. 26. Inspect seat belt warning system (inspect integration relay operation) : a. Connect the positive (+) lead from the battery to terminals 3 and 9. b. Connect the terminal 7 to terminal 9 through the 3.4 W test bulb. c. Connect the negative (-) lead from the battery to terminal 7.

2002 ACCESSORIES & EQUIPMENT Combination Meter - Corolla

Fig. 38: Testing Seat Belt Warning System & Integration Relay (1 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. d. Check that the bulb lights and the buzzer sounds for 48 second.

2002 ACCESSORIES & EQUIPMENT Combination Meter - Corolla

Fig. 39: Testing Seat Belt Warning System & Integration Relay (1 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. e. Return to step ( ) and operate the buzzer sound again. f. Connect the negative (-) lead from the battery to terminal 3. NOTE: Check the buzzer within a period of 4 to 8 seconds.

g. Check that the buzzer stops sounding. If operation is not as specified, replace the relay. 27. Inspect seat belt warning system (inspect integration relay circuit. See INSPECTION .

2002 ACCESSORIES & EQUIPMENT Defogger System - Corolla

2002 ACCESSORIES & EQUIPMENT Defogger System - Corolla

DEFOGGER SYSTEM
NOTE: For manufacturers precautions, see BODY, CAB CONTROL SYSTEMS . For circuit troubleshooting, see DEFOGGER SYSTEM . For circuit wiring diagrams, see DEFOGGERS .

LOCATION

2002 ACCESSORIES & EQUIPMENT Defogger System - Corolla

Fig. 1: Locating Defogger System Components Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSPECTION 1. Inspect defogger switch continuity : Connect the positive (+) lead from the battery to terminal 1 and negative (-) lead to terminal 8, check that the indicator light up.

2002 ACCESSORIES & EQUIPMENT Defogger System - Corolla

Fig. 2: Identifying & Testing Defogger Switch & Terminals Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. If operation is not as specified, replace the switch. 2. Inspect defogger timer operation : a. Connect the positive (+) lead from the battery to terminal 1 and negative (-) lead to terminal 8.

2002 ACCESSORIES & EQUIPMENT Defogger System - Corolla

Fig. 3: Testing Defogger Timer Operation Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Connect the positive (+) lead from the battery to terminal 2 through a 1.4 W test bulb. c. Push the defogger switch ON and check that the indicator light in switch and test bulb light up for 12 for 18 minutes, then the indicator light and test bulb lights go out. If operation is not as specified, replace the switch. 3. Inspect defogger switch circuit : Disconnect the connector from the switch and inspect the connector on the wire harness side, as shown in the chart.

2002 ACCESSORIES & EQUIPMENT Defogger System - Corolla

Fig. 4: Identifying Defogger Switch Terminals Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 5: Defogger Switch Specifications Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. If the circuit is as specified, replace the switch. 4. Inspect defogger relay continuity :

2002 ACCESSORIES & EQUIPMENT Defogger System - Corolla

Fig. 6: Identifying Defogger Relay Terminals & Wiring Diagram Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 7: Defogger Relay Specifications Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. If continuity is not as specified, replace the relay. 5. Inspect defogger wire : NOTE:

When cleaning the glass, use a soft, dry cloth, and wipe the glass in the direction of the wire. Take care not to damage the wires. Do not use detergents or glass cleaners with abrasive ingredients.

2002 ACCESSORIES & EQUIPMENT Defogger System - Corolla

When measuring voltage, wind a piece of tin foil around the top of the negative probe and press the foil against the wire with your finger.

Fig. 8: Procedure For Probing Defogger Wire Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. a. Turn the ignition switch ON. b. Turn the defogger switch ON. NOTE: If there is approximately 10 V, the wire is broken between the center of the wire and the positive (+) end. If there is no voltage, the wire is broken between the center of the wire and ground.

2002 ACCESSORIES & EQUIPMENT Defogger System - Corolla

Fig. 9: Identifying Defogger Wire Probing Points Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 10: Defogger Wire Specifications Chart Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Inspect the voltage at the center of each heat wire. d. Place the voltmeter positive (+) lead against the defogger positive (+) terminal. e. Place the voltmeter negative (-) lead with the foil strip against the heat wire at the positive (+) terminal end and slide it toward the negative (-) terminal end. NOTE: If the heat wire is not broken, the voltmeter indicates 0 V at the positive (+) end of the heat wire but gradually increases to about 12 V as the meter probe is moved to the other end.

2002 ACCESSORIES & EQUIPMENT Defogger System - Corolla

Fig. 11: Locating Defogger Wire Break Point Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. f. The point where the voltmeter deflects from zero to several V is the place where the heat wire is broken. a. If necessary, repair defogger wire : a. Clean the broken wire tips with grease, wax and silicone remover. b. Place the masking tape along both sides of the wire for repair.

2002 ACCESSORIES & EQUIPMENT Defogger System - Corolla

Fig. 12: Preparing Defogger Wire For Repair Agent Application Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Thoroughly mix the repair agent (Dupont paste No. 4817). d. Using a fine tip brush, apply a small amount of the agent to the wire.

2002 ACCESSORIES & EQUIPMENT Defogger System - Corolla

Fig. 13: Applying Repair Agent Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. e. After a few minutes, remove the masking tape. f. Do not repair the defogger wire for at least 24 hours.

2002 ACCESSORIES & EQUIPMENT Ignition Switch & Key Unlock Warning Switch - Corolla

2002 ACCESSORIES & EQUIPMENT Ignition Switch & Key Unlock Warning Switch - Corolla

IGNITION SWITCH AND KEY UNLOCK WARNING SWITCH

NOTE: For manufacturers precautions, see BODY, CAB CONTROL SYSTEMS . For circuit troubleshooting, see IGNITION SWITCH AND KEY UNLOCK WARNING SWITCH . For circuit wiring diagrams, see POWER DISTRIBUTION .

LOCATION

Fig. 1: Locating Ignition Switch & Key Unlock Warning Switch Components Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 ACCESSORIES & EQUIPMENT Ignition Switch & Key Unlock Warning Switch - Corolla

INSPECTION 1. Inspect ignition switch continuity :

Fig. 2: Identifying Ignition Switch Positions & Terminals Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 3: Ignition Switch Position Specifications Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. If continuity is not as specified, replace the switch. 2. Inspect key unlock warning switch continuity :

2002 ACCESSORIES & EQUIPMENT Ignition Switch & Key Unlock Warning Switch - Corolla

Fig. 4: Identifying Key Unlock Warning Switch Positions & Terminals Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 5: Key Unlock Warning Switch Specifications Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. If continuity is not as specified, replace the switch. 3. Inspect key unlock warning system (inspect integration relay operation) : a. Connect the positive (+) lead from the battery to terminal 3.

2002 ACCESSORIES & EQUIPMENT Ignition Switch & Key Unlock Warning Switch - Corolla

Fig. 6: Testing Key Unlock Warning/Integration Relay (1 Of 3) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Connect the negative (-) lead from the battery to terminals 4, 7 and 8.

2002 ACCESSORIES & EQUIPMENT Ignition Switch & Key Unlock Warning Switch - Corolla

Fig. 7: Testing Key Unlock Warning/Integration Relay (2 Of 3) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. d. e. f. Check that the buzzer sounds. Disconnect the negative (-) lead from the battery to terminal 8. Check that the buzzer stops sounding. Connect the negative (-) lead from the battery to terminal 8 and operate the buzzer sound again.

2002 ACCESSORIES & EQUIPMENT Ignition Switch & Key Unlock Warning Switch - Corolla

Fig. 8: Testing Key Unlock Warning/Integration Relay (1 Of 3) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. g. Disconnect the negative (-) lead from the battery to terminal 4. h. Check that the buzzer stops sounding. If operation is not as specified, replace the relay. 4. Inspect integration relay circuit : a. Disconnect the connector from the integration relay and inspect the connectors on the wire harness side.

2002 ACCESSORIES & EQUIPMENT Ignition Switch & Key Unlock Warning Switch - Corolla

Fig. 9: Identifying Integration Relay Terminals (Wire Harness Side) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 10: Integration Relay Terminal Specifications (Wire Harness Side) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. If the circuit is not as specified, inspect the circuits connected to other parts. b. Remove the integration relay from the instrument panel junction block and inspect the connectors on the junction block side.

2002 ACCESSORIES & EQUIPMENT Ignition Switch & Key Unlock Warning Switch - Corolla

Fig. 11: Identifying Integration Relay Terminals (Junction Block Side) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 12: Integration Relay Terminal Specifications (Junction Block Side) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. If the circuit is as specified, try replacing the relay with a new one. If the circuit is not as specified, inspect the circuits connected to other parts.

2002 ACCESSORIES & EQUIPMENT Power Mirror Control System - Corolla

2002 ACCESSORIES & EQUIPMENT Power Mirror Control System - Corolla

POWER MIRROR CONTROL SYSTEM

NOTE: For manufacturers precautions, see BODY, CAB CONTROL SYSTEMS . For circuit troubleshooting, see POWER MIRROR CONTROL SYSTEM . For wiring diagram, see POWER MIRRORS .

LOCATION

2002 ACCESSORIES & EQUIPMENT Power Mirror Control System - Corolla

Fig. 1: Locating Power Mirror Control System Components Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSPECTION 1. Inspect mirror switch continuity ,

2002 ACCESSORIES & EQUIPMENT Power Mirror Control System - Corolla

2002 ACCESSORIES & EQUIPMENT Power Mirror Control System - Corolla

Fig. 2: Identifying Left/Right Adjustment Switch Terminals & Positions Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Left side for left/right adjustment switch:

Fig. 3: Mirror Control Switch Specifications Chart (Left Side) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Right side for left/right adjustment switch:

2002 ACCESSORIES & EQUIPMENT Power Mirror Control System - Corolla

Fig. 4: Mirror Control Switch Specifications Chart (Right Side) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. If continuity is not as specified, replace the switch. 2. Inspect mirror motor operation : a. Connect the positive (+) lead from the battery to terminal 3 and the negative (-) lead to terminal 2, and check that the mirror turns upward.

2002 ACCESSORIES & EQUIPMENT Power Mirror Control System - Corolla

Fig. 5: Testing Mirror Motor (1 Of 4) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Reverse the polarity, and check that the mirror turns downward.

2002 ACCESSORIES & EQUIPMENT Power Mirror Control System - Corolla

Fig. 6: Testing Mirror Motor (2 Of 4) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Connect the positive (+) lead from the battery to terminal 1 and the negative (-) lead to terminal 2, and check that the mirror turns to the left side.

2002 ACCESSORIES & EQUIPMENT Power Mirror Control System - Corolla

Fig. 7: Testing Mirror Motor (3 Of 4) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. d. Reverse the polarity, and check that the mirror turns to the right side.

2002 ACCESSORIES & EQUIPMENT Power Mirror Control System - Corolla

Fig. 8: Testing Mirror Motor (4 Of 4) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. If operation is not as specified, replace the mirror.

2002 ACCESSORIES & EQUIPMENT Power Window Control System - Corolla

2002 ACCESSORIES & EQUIPMENT Power Window Control System - Corolla

POWER WINDOW CONTROL SYSTEM

NOTE: For manufacturers precautions, see BODY, CAB CONTROL SYSTEMS . For circuiT troubleshooting, see POWER WINDOW CONTROL SYSTEM . For circuit wiring diagrams, see POWER WINDOWS .

LOCATION

2002 ACCESSORIES & EQUIPMENT Power Window Control System - Corolla

Fig. 1: Locating Power Window Control System Components Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSPECTION 1. Inspect power window master switch continuity : Front driver's switch (Window unlock and lock):

2002 ACCESSORIES & EQUIPMENT Power Window Control System - Corolla

Fig. 2: Identifying Power Window Master Switch Terminals Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 ACCESSORIES & EQUIPMENT Power Window Control System - Corolla

Fig. 3: Master Switch Specifications For Front Driver's Switch (Window Lock & Unlock) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 4: Master Switch Specifications For Front Passenger's Switch (Window Unlock) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 5: Master Switch Specifications For Front Passenger's Switch (Window Lock) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 ACCESSORIES & EQUIPMENT Power Window Control System - Corolla

Fig. 6: Master Switch Specifications For Rear Left Switch (Window Unlock) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 7: Master Switch Specifications For Rear Left Switch (Window Lock) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 8: Master Switch Specifications For Rear Right Switch (Window Unlock) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 ACCESSORIES & EQUIPMENT Power Window Control System - Corolla

Fig. 9: Master Switch Specifications For Rear Right Switch (Window Lock) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. If continuity is not as specified, replace the master switch. 2. Inspect power window master switch illumination : Connect the positive (+) lead from the battery to terminal 11 and the negative (-) lead to terminal 4, and check that all the illuminations light up.

Fig. 10: Testing Power Window Master Switch Illumination Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. If operation is not as specified, replace the master switch. 3. Using an ammeter, inspect one touch power window system current of circuit : a. Disconnect the connector from the master switch.

2002 ACCESSORIES & EQUIPMENT Power Window Control System - Corolla

b. Connect the positive (+) lead from the ammeter to terminal 5 on the wire harness side connector and the negative (-) lead to negative (-) terminal of the battery.

Fig. 11: Testing One Touch Power Window Circuit Using An Ammeter (1 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Connect the positive (+) lead from the battery to terminal 1 on the wire harness side connector.

2002 ACCESSORIES & EQUIPMENT Power Window Control System - Corolla

Fig. 12: Testing One Touch Power Window Circuit Using An Ammeter (2 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE: The circuit breaker opens some 4-40 seconds after the window stops going down, so that check must be made before the circuit breaker operates.

d. As the window goes down, check that the current flow is approximately 7 A. Check that the current increases up to approximately 14.5 A or more when the window stops going down. If the operation is as specified, replace the master switch. 4. Using an ammeter with a current-measuring probe, inspect one touch power window system current of circuit : a. Remove the master switch with connector connected. b. Attach a current-measuring probe to terminal 5 of the wire harness.

2002 ACCESSORIES & EQUIPMENT Power Window Control System - Corolla

Fig. 13: Testing One Touch Power Window Circuit Using An Ammeter With Current Probe (1 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Turn the ignition switch ON and set the power window switch in the down position. d. As the window goes down, check that the current flow is approximately 7 A. NOTE: The circuit breaker opens some 4 - 40 seconds after the window stops going down, so that check must be made before the circuit breaker operates.

2002 ACCESSORIES & EQUIPMENT Power Window Control System - Corolla

Fig. 14: Testing One Touch Power Window Circuit Using An Ammeter With Current Probe (2 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. e. Check that the current increases up to approximately 14.5 A or more when the window stops going down. If operation is as specified, replace the master switch. 5. Inspect passenger's power window switch continuity :

2002 ACCESSORIES & EQUIPMENT Power Window Control System - Corolla

Fig. 15: Identifying Passenger's Power Window Switch Terminals Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 16: Passenger's Power Window Switch Specifications Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. If continuity is not as specified, replace the switch. 6. Inspect rear door power window switch continuity :

2002 ACCESSORIES & EQUIPMENT Power Window Control System - Corolla

Fig. 17: Identifying Rear Door Power Window Switch Terminals Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 18: Rear Door Power Window Switch Specifications Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. If continuity is not as specified, replace the switch. 7. Left side door, inspect power window motor operation : a. Connect the positive (+) lead from the battery to terminal 1 and the negative (-) lead to terminal 2, and check that the motor turns clockwise.

2002 ACCESSORIES & EQUIPMENT Power Window Control System - Corolla

Fig. 19: Testing Left Side Door Power Window Motor (1 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Reverse the polarity, check that the motor turns counterclockwise.

2002 ACCESSORIES & EQUIPMENT Power Window Control System - Corolla

Fig. 20: Testing Left Side Door Power Window Motor (2 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. If operation is not as specified, replace the motor. 8. Right side door, inspect power window motor operation : a. Connect the positive (+) lead from the battery to terminal 1 and the negative (-) lead to terminal 2, and check that the motor turns clockwise.

2002 ACCESSORIES & EQUIPMENT Power Window Control System - Corolla

Fig. 21: Testing Right Side Door Power Window Motor (1 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Reverse the polarity, check that the motor turns counterclockwise.

2002 ACCESSORIES & EQUIPMENT Power Window Control System - Corolla

Fig. 22: Testing Right Side Door Power Window Motor (2 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. If operation is not as specified, replace the motor. 9. Driver's door, inspect power window motor circuit breaker operation : a. Disconnect the connector from the master switch. b. Connect the positive (+) lead from the battery to terminal 5 and the negative (-) lead to terminal 1 on the wire harness side connector and raise the window to full closed position.

2002 ACCESSORIES & EQUIPMENT Power Window Control System - Corolla

Fig. 23: Testing Driver's Door Power Window Motor Circuit Breaker (1 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Continue to apply voltage, check that there is a circuit breaker operation noise within approximately 4 to 40 seconds. d. Reverse the polarity, check that the window begins to descend within approximately 60 seconds.

2002 ACCESSORIES & EQUIPMENT Power Window Control System - Corolla

Fig. 24: Testing Driver's Door Power Window Motor Circuit Breaker (2 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. If operation is not as specified, replace the motor. 10. Front passenger's door, inspect power window motor circuit breaker operation : a. Disconnect the connector from the power window switch. b. Connect the positive (+) lead from the battery to terminal 3 and the negative (-) lead to terminal 1 on the wire harness side connector, and raise the window to full closed position.

2002 ACCESSORIES & EQUIPMENT Power Window Control System - Corolla

Fig. 25: Testing Driver's Door Power Window Motor Circuit Breaker (1 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Continue to apply voltage, check that there is a circuit breaker operation noise within approximately 4 to 40 seconds. d. Reverse the polarity, check that the window begins to descend within approximately 60 seconds.

2002 ACCESSORIES & EQUIPMENT Power Window Control System - Corolla

Fig. 26: Testing Driver's Door Power Window Motor Circuit Breaker (2 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. If operation is not as specified, replace the motor. 11. Rear left side door, inspect power window motor circuit breaker operation : Repeat steps -c for rear door. 12. Rear right side door, inspect power window motor circuit breaker operation : Repeat steps -c for rear door. 13. Inspect power main relay continuity :

2002 ACCESSORIES & EQUIPMENT Power Window Control System - Corolla

Fig. 27: Identifying Power Main Relay Terminals & Wiring Diagram Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 28: Identifying Power Main Relay Specifications Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. If continuity is not as specified, replace the relay. NOTE: When the relay circuit is as specified, inspect the key-off power window signal.

14. Key-Off power window signal, inspect integration relay operation : a. Connect the positive (+) lead from the voltmeter to terminal 14 and the negative (-) lead to body

2002 ACCESSORIES & EQUIPMENT Power Window Control System - Corolla

ground.

Fig. 29: Testing Integration Relay Operation (1 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Close the door with ignition switch turned to LOCK or ACC, and check that the meter needle indicates battery positive voltage. c. Open the door and check that the meter needle indicates 0 V. d. Turn the ignition switch ON and check that the meter needle indicates battery positive voltage again.

2002 ACCESSORIES & EQUIPMENT Power Window Control System - Corolla

Fig. 30: Testing Integration Relay Operation (2 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. If operation is not as specified, replace the relay. 15. Inspect integration relay circuit . See INSPECTION .

2002 ACCESSORIES & EQUIPMENT Wiper/Washer Systems - Corolla

2002 ACCESSORIES & EQUIPMENT Wiper/Washer Systems - Corolla

WIPER AND WASHER SYSTEM

NOTE: For manufactures precautions, see BODY, CAB CONTROL SYSTEMS . For circuit troubleshooting, see WIPER AND WASHER . For circuit wiring diagrams, see WIPER/WASHER .

LOCATION

2002 ACCESSORIES & EQUIPMENT Wiper/Washer Systems - Corolla

Fig. 1: Locating Wiper & Washer System Components Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSPECTION 1. Inspect wiper and washer switch continuity :

2002 ACCESSORIES & EQUIPMENT Wiper/Washer Systems - Corolla

Fig. 2: Identifying Wiper & Washer Switch Positions & Locating Terminals Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 ACCESSORIES & EQUIPMENT Wiper/Washer Systems - Corolla

Fig. 3: Wiper & Washer Switch Specifications Chart Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. If continuity is not as specified, replace the switch. 2. Inspect wiper intermittent operation : a. Turn the wiper switch to INT position. b. Turn the intermittent time control switch to FAST position. c. Connect the positive (+) lead from the battery to terminal 16 and the negative (-) lead to terminal 2.

2002 ACCESSORIES & EQUIPMENT Wiper/Washer Systems - Corolla

Fig. 4: Testing Intermittent Operation (1 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. d. Connect the positive (+) lead from the voltmeter to terminal 7 and the negative (-) lead to terminal 2, check that the meter needle indicates battery positive voltage.

2002 ACCESSORIES & EQUIPMENT Wiper/Washer Systems - Corolla

Fig. 5: Intermittent Operation Chart Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. e. After connecting terminal 16 to terminal 17, connect to terminal 2 to terminal 17, check the voltage rises from 0 volts to battery positive voltage with in the times, as shown in the table.

2002 ACCESSORIES & EQUIPMENT Wiper/Washer Systems - Corolla

Fig. 6: Testing Intermittent Operation (2 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. If operation is not as specified, replace the wiper and washer switch. 3. Inspect washer linked operation : a. Connect the positive (+) lead from the battery to terminal 16 and the negative (-) lead to terminal 2.

2002 ACCESSORIES & EQUIPMENT Wiper/Washer Systems - Corolla

Fig. 7: Testing Washer Linked Operation Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Connect the positive (+) lead from the voltmeter to terminal 7 and the negative (-) lead to terminal 2. c. Push in the washer switch, and check that the voltage changes as shown in the table.

2002 ACCESSORIES & EQUIPMENT Wiper/Washer Systems - Corolla

Fig. 8: Washer Linked Operation Chart Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. If operation is not as specified, replace the wiper and washer switch. 4. Low speed, inspect wiper motor operation : Connect the positive (+) lead from the battery to terminal 3 and the negative (-) lead to terminal 1, check that the motor operates at low speed.

2002 ACCESSORIES & EQUIPMENT Wiper/Washer Systems - Corolla

Fig. 9: Testing Low Speed Wiper Motor Operation (Denso Made) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 ACCESSORIES & EQUIPMENT Wiper/Washer Systems - Corolla

Fig. 10: Testing Low Speed Wiper Motor Operation (ITT Made) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. If operation is not as specified, replace the motor. 5. High speed, inspect wiper motor operation : Connect the positive (+) lead from the battery to terminal 2 and the negative (-) lead to terminal 1, check that the motor operates at high speed.

2002 ACCESSORIES & EQUIPMENT Wiper/Washer Systems - Corolla

Fig. 11: Testing High Speed Wiper Motor Operation (Denso Made) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 ACCESSORIES & EQUIPMENT Wiper/Washer Systems - Corolla

Fig. 12: Testing High Speed Wiper Motor Operation (ITT Made) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. If operation is not as specified, replace the motor. 6. Stopping at stop position, inspect wiper motor operation : a. Operate the motor at low speed and stop the motor operation anywhere except at the stop position by disconnecting positive (+) lead from terminal 3.

2002 ACCESSORIES & EQUIPMENT Wiper/Washer Systems - Corolla

Fig. 13: Testing Wiper Motor Stop Position (Denso Made 1 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 ACCESSORIES & EQUIPMENT Wiper/Washer Systems - Corolla

Fig. 14: Testing Wiper Motor Stop Position (ITT Made 1 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Connect terminals 3 and 5. c. Connect the positive (+) lead from the battery to terminal 6 and negative (-) lead to terminal 1, check that the motor stops running at the stop position after the motor operates again.

2002 ACCESSORIES & EQUIPMENT Wiper/Washer Systems - Corolla

Fig. 15: Testing Wiper Motor Stop Position (Denso Made 2 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 ACCESSORIES & EQUIPMENT Wiper/Washer Systems - Corolla

Fig. 16: Testing Wiper Motor Stop Position (ITT Made 2 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. If operation is not as specified, replace the motor. NOTE: These tests must be performed quickly (within 20 seconds) to prevent the coil from burning out.

2002 ACCESSORIES & EQUIPMENT Wiper/Washer Systems - Corolla

Fig. 17: Testing Washer Motor Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 7. Inspect washer motor operation : Connect the positive (+) lead from the battery to terminal 2 and the negative (-) lead to terminal 1, check that the motor operates. If operation is not as specified, replace the motor.

2002 ACCESSORIES & EQUIPMENT Sliding Roof System - Corolla

2002 ACCESSORIES & EQUIPMENT Sliding Roof System - Corolla

SLIDING ROOF SYSTEM

NOTE: For manufacturers precautions, see BODY, CAB CONTROL SYSTEMS . For circuit troubleshooting, see SLIDING ROOF SYSTEM . For wiring diagram, see POWER TOP/SUNROOF .

LOCATION

2002 ACCESSORIES & EQUIPMENT Sliding Roof System - Corolla

Fig. 1: Locating Sliding Roof System Components Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSPECTION 1. Inspect sliding roof switch continuity :

2002 ACCESSORIES & EQUIPMENT Sliding Roof System - Corolla

Fig. 2: Identifying Sliding Roof Switch Terminals & Positions Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 3: Sliding Roof Switch Terminal Specifications Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. If continuity is not as specified, replace the switch.

2002 ACCESSORIES & EQUIPMENT Sliding Roof System - Corolla

2. Inspect sliding roof limit switch continuity :

Fig. 4: Identifying Limit Switches & Terminals Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 5: Limit Switch Specifications Chart Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. If continuity is not as specified, replace the switch. 3. Inspect sliding roof motor operation :

2002 ACCESSORIES & EQUIPMENT Sliding Roof System - Corolla

a. Connect the positive (+) lead from the battery to terminal 2 and the negative (-) lead to terminal 1, check that the motor turns clockwise (moves of the close side).

Fig. 6: Testing Sliding Roof Motor (1 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Reverse the polarity, check that the motor turns counter-clockwise. (moves to the open side).

2002 ACCESSORIES & EQUIPMENT Sliding Roof System - Corolla

Fig. 7: Testing Sliding Roof Motor (2 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. If operation is not as specified, replace the motor. 4. Inspect sliding roof motor circuit breaker operation : a. With the sliding roof in the fully opened position, hold the sliding roof switch in "OPEN" position and check that there is a circuit breaker operation noise within 10 to 60 seconds.

2002 ACCESSORIES & EQUIPMENT Sliding Roof System - Corolla

Fig. 8: Testing Sliding Roof Circuit Breaker (1 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. With the sliding roof in the fully opened position, hold the sliding roof switch in "CLOSE" position and check that the sliding roof begins to close within 60 seconds.

2002 ACCESSORIES & EQUIPMENT Sliding Roof System - Corolla

Fig. 9: Testing Sliding Roof Circuit Breaker (2 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. If operation is not as specified, replace the motor. 5. Inspect power main relay continuity :

2002 ACCESSORIES & EQUIPMENT Sliding Roof System - Corolla

Fig. 10: Identifying Power Main Relay Terminals & Wiring Diagram Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 11: Power Main Relay Specifications Chart Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. If continuity is not as specified, replace the relay. 6. Inspect sliding roof control relay circuit : Disconnect the connector from the relay and switch and inspect the connector on the wire harness side, as shown in the specifications chart.

2002 ACCESSORIES & EQUIPMENT Sliding Roof System - Corolla

Fig. 12: Identifying Roof Control Relay Terminals (Wire Harness Side) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 ACCESSORIES & EQUIPMENT Sliding Roof System - Corolla

Fig. 13: Roof Control Relay Terminal Specifications Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 BRAKES Brake - Troubleshooting - Corolla

2002 BRAKES Brake - Troubleshooting - Corolla

TROUBLESHOOTING
PRECAUTION

Care must be taken to replace each part properly as it could affect the performance of the brake system and result in a driving hazard. Replace the parts with parts having the same part number or equivalent. It is very important to keep parts and the area clean when repairing the brake system. If the vehicle is equipped with a mobile communication system, refer to the precaution in the IN section.

PROBLEM SYMPTOMS Use PROBLEM SYMPTOMS to help you find the cause of the problem. The numbers indicate the priority of the likely cause of the problem. Check each part in order. If necessary, replace these parts. PROBLEM SYMPTOMS Symptom/Suspect Area Lower Pedal Or Spongy Pedal Brake System (Fluid Leaks) Brake System (Air In) Piston Seals (Worn Or Damaged) Rear Brake Shoe Clearance (Out Of Adjustment) Master Cylinder (Faulty) Booster Push Rod (Out Of Adjustment) Brake Drag Brake Pedal Freeplay (Minimal) Parking Brake Lever Travel (Out Of Adjustment) Parking Brake Wire (Sticking) Rear Brake Shoe Clearance (Out Of Adjustment) Pad Or Lining (Cracked Or Distorted) Piston (Stuck) Piston (Frozen) Anchor Or Return Spring (Faulty) Booster Push Rod (Out Of Adjustment) Booster System (Vacuum Leaks)

See Check For Leaks BLEEDING PROCEDURES

(1) (4) (5) (3)

BRAKE PEDAL FREE PLAY PARKING BRAKE LEVER Check Parking Brake Wire
(4) (1) , (2) (1) , (2) (1) , (2) (2) (3) (6)

2002 BRAKES Brake - Troubleshooting - Corolla

Master Cylinder (Faulty) Brake Pull Piston (Stuck) Pad Or Lining (Oily) Piston (Frozen) Disc (Scored) Pad Or Lining (Cracked Or Distorted) Hard Pedal But Brake Inefficient Brake System (Fluid Leaks) Brake System (Air In) Pad Or Lining (Worn) Pad Or Lining (Cracked Or Distorted) Rear Brake Shoe Clearance (Out Of Adjustment) Pad Or Lining (Oily) Pad Or Lining (Glazed) Disc (Scored) Booster Push Rod (Out Of Adjustment) Booster System (Vacuum Leaks) Noise From Brake Pad Or Lining (Cracked Or Distorted) Installation Bolt (Loosen) Disc (Scored) Pad Support Plate (Loosen) Sliding Pin (Worn) Pad Or Lining (Dirty) Pad Or Lining (Glazed) Anchor Or Return Spring (Faulty) Anti-Squeal Shim (Damage) Hold-Down Spring (Damage)
(1) See exploded view of front brake components under INSTALLATION . (2) See exploded view of rear brake components under REMOVAL & INSTALLATION . (3) See BRAKE BOOSTER PUSH ROD . (4) See DRUM BRAKES (5) See appropriate figures under INSTALLATION . (6) See LEAK TEST .

(5) (1) , (2) (1) , (2) (1) , (2) (1) (1) , (2)

Check For Leaks BLEEDING PROCEDURES

(1) , (2) (1) , (2) (4) (1) , (2) (1) , (2) (1) (3) (6) (1) , (2) (1) (1) (1) (1) (1) , (2) (1) , (2) (2) (1) (2)

2002 BRAKES Disc & Drum - Corolla

2002 BRAKES Disc & Drum - Corolla

DESCRIPTION & OPERATION

WARNING: For warnings and procedures regarding vehicles equipped with AntiLock Brake Systems (ABS), see appropriate ANTI-LOCK article. The hydraulic brake system uses a tandem master cylinder with vacuum power assist servo. Corolla is equipped with standard front disc and rear drum brakes. A proportioning valve is used to regulate brake pressure between front and rear brakes. Rear drum brakes on all models are self-adjusting. Parking brake lever mechanically activates rear brakes. A cable applies rear shoes. ABS actuator is located on or near master cylinder.

BLEEDING BRAKE SYSTEM

BLEEDING PROCEDURES CAUTION: DO NOT allow reservoir to run dry during brake bleeding procedure. Use only clean brake fluid. Ensure no dirt or other foreign matter contaminates brake fluid. DO NOT mix different brands of brake fluid, as they may not be compatible. DO NOT spill brake fluid on vehicle, as it may damage paint. If brake fluid contacts paint, immediately wash with water. 1. If master cylinder is rebuilt or reservoir is empty, bleed master cylinder first. Bleed wheels in sequence. Start on wheel with longest hydraulic line, and work toward wheel with shortest hydraulic line. 2. Raise and support vehicle. Ensure brake fluid reservoir is at least half full during bleeding procedure. Connect one end of transparent vinyl tube to bleed screw. Submerge other end of tube in a container half filled with clean brake fluid. 3. Have an assistant depress brake pedal several times and hold in depressed position. Loosen bleed screw, and drain fluid into container. Tighten bleed screw. NOTE: Ensure brake pedal remains depressed until bleed screw is tightened.

4. Refill brake fluid reservoir as necessary. Repeat step 3 until air is no longer discharged. Tighten bleed screw to 74 INCH lbs. (8 N.m). Ensure fluid leakage is not present. Add fluid to reservoir. Repeat procedure for remaining wheels.

ADJUSTMENTS
BRAKE PEDAL HEIGHT

2002 BRAKES Disc & Drum - Corolla

1. Measure brake pedal height from face of pedal pad to asphalt sheet under carpet. See Fig. 1 . If pedal height adjustment is necessary, loosen stoplight switch and lock nut on brake push rod. Turn push rod to adjust height. See BRAKE PEDAL HEIGHT SPECIFICATIONS table. 2. After setting pedal height, tighten lock nut on push rod. See TORQUE SPECIFICATIONS . Adjust stoplight switch, and tighten switch lock nut. See STOPLIGHT SWITCH . BRAKE PEDAL HEIGHT SPECIFICATIONS Application Corolla

In. (mm) 5.86-6.24 (148.8-158.4)

Fig. 1: Measuring Pedal Height & Free Play Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. BRAKE PEDAL FREE PLAY 1. Brake pedal free play is distance brake pedal travels with engine off before resistance is felt. See Fig. 1 . To check pedal free play, depress brake pedal several times to exhaust vacuum from power brake unit. 2. Depress pedal until initial resistance is felt, and measure distance traveled. Brake pedal free play should be .04-.24" (1.0-6.1 mm). If free play is not as specified, adjust by turning push rod. Check brake pedal height. See BRAKE PEDAL HEIGHT . BRAKE PEDAL DEPRESSED HEIGHT 1. Measure pedal depressed height with engine running and weight of 110 lbs. (50 kg) applied against pedal. Measure pedal depressed height from face of pedal pad to asphalt sheet under carpet.

2002 BRAKES Disc & Drum - Corolla

2. If measured depressed height is less than specification, inspect brake system. See BRAKE PEDAL MINIMUM DEPRESSED HEIGHT table. BRAKE PEDAL MINIMUM DEPRESSED HEIGHT Application With ABS Without ABS PROPORTIONING VALVE ("P" VALVE - NON-LOAD SENSING TYPE) NOTE: See PROPORTIONING VALVE ("P" VALVE - NON-LOAD SENSING TYPE) under TESTING.

In. (mm) 3.54 (89.9) 3.35 (85.1)

PARKING BRAKE LEVER NOTE: Adjust rear brake shoe clearance before adjusting parking brake. See REAR BRAKE SHOES .

Inspection

To check parking brake adjustment, pull parking brake lever with force of 44 lbs. (20 kg). Count number of notches (clicks). Adjust parking brake if lever stroke (number of notches) is not as specified. See PARKING BRAKE LEVER STROKE SPECIFICATIONS table.
Adjustment

Remove center console or parking brake lever boot to uncover base of lever. Loosen lock nut. Turn adjuster nut on cable until lever stroke is correct. Tighten lock nut. Install console or boot. PARKING BRAKE LEVER OR PEDAL STROKE SPECIFICATIONS Application Corolla REAR BRAKE SHOES NOTE: All rear drum brakes have a self-adjuster, which is activated when brake pedal is applied as vehicle travels in Reverse.

Notches 4-7

Drum Brakes

Raise and support rear of vehicle. Remove rear wheel. Release parking brake. Measure drum inner diameter and brake shoe diameter. Difference between drum and shoe diameters is clearance. Measured clearance should be .024" (.61 mm). BRAKE BOOSTER PUSH ROD Check and adjust clearance between brake booster push rod and master cylinder piston, if either unit is replaced or overhauled. See Fig. 2 . Clearance should be zero. If clearance is not as specified, adjust male

2002 BRAKES Disc & Drum - Corolla

portion of push rod using open-end wrench while holding female portion of push rod with pliers.

Fig. 2: Measuring Clearance Between Master Cylinder Piston & Brake Booster Push Rod Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. STOPLIGHT SWITCH Remove lower instrument panel and air duct (if necessary). Loosen lock nut. Turn switch until clearance between switch and pedal stop is .02-.09" (.5-2.4 mm). See Fig. 1 . Check brake pedal height. See BRAKE PEDAL HEIGHT . Check brakelight operation.

TESTING
BRAKE BOOSTER
Functional Test

1. Start engine. Turn ignition off. Depress brake pedal several times. Depress pedal firmly and hold for 15 seconds. If pedal sinks, master cylinder, brakeline or caliper piston is faulty. 2. Start engine with pedal depressed. If pedal sinks slightly, vacuum unit is working properly. If pedal height does not vary, brake booster or check valve is faulty. Replace as necessary.
Leak Test

1. Depress brake pedal with engine running. Hold brake pedal in depressed position, and turn ignition off. If pedal height does not vary within 30 seconds, vacuum booster is okay. If pedal height changes, check for air leaks. 2. With engine stopped, depress brake pedal several times using normal pressure. Pedal height should be low when first depressed. On consecutive applications, pedal height should gradually increase. If pedal height does not increase, check for air leaks. PROPORTIONING VALVE ("P" VALVE - NON-LOAD-SENSING TYPE)

2002 BRAKES Disc & Drum - Corolla

1. Install pressure gauge set to front caliper and opposite side rear wheel cylinder. Bleed air from pressure gauge. Increase master cylinder (front) pressure to indicated value, and read rear wheel pressure gauges. Repeat procedure using full force, and recheck pressure gauges. See PROPORTIONING VALVE PRESSURE SPECIFICATIONS table. 2. Rear pressure increase should be as specified. If rear wheel cylinder pressure is not as specified, replace "P" valve assembly. PROPORTIONING VALVE PRESSURE SPECIFICATIONS Application Front Pressure - psi (kg/cm2 ) With ABS ..... Without ABS ..... 284 (20) 1138 (80) 427 (30) 1138 (80)

Rear Pressure - psi (kg/cm2 ) 284 (20.0) 685 (48.2) 427 (30.0) 605 (42.5)

REMOVAL & INSTALLATION

FRONT DISC BRAKE PADS NOTE: Location and number of anti-rattle springs, anti-squeal shims and pad support plates vary by model. Note component locations during removal for installation reference.

Removal

1. Raise and support vehicle. Remove wheel and tire assembly. Temporarily install wheel lug nuts to retain rotor position. Remove brake caliper from torque plate and wire aside, leaving brakeline connected. See Fig. 3 . 2. Remove anti-rattle springs (if equipped), anti-squeal shims and pads. Remove pad support plates and pad wear indicators. Check rotor thickness and runout. Measure brake pads and replace if necessary. See appropriate table under DISC & DRUM BRAKE SPECIFICATIONS . NOTE: Some models have one or more sets of anti-squeal shims. If one set of shims is vented, place it between pad and outer anti-squeal shim.

Installation

1. Install pad support plates and NEW pads. Install pad wear indicators, anti-squeal shims and anti-rattle springs (if equipped). Apply disc brake grease to inner anti-squeal shims. DO NOT allow grease to contact rubbing face of pads. Wear indicator must be on top side of pad. NOTE: Pushing piston into caliper bore forces fluid back into master cylinder reservoir. Remove reservoir cap when compressing piston.

2. Press piston into caliper bore. DO NOT let piston dust boot wedge against edge of pads. To complete installation, reverse removal procedure. Tighten bolts to specification. See TORQUE SPECIFICATIONS . Check reservoir fluid level.

2002 BRAKES Disc & Drum - Corolla

Fig. 3: Exploded View Of Front Brake Assembly (Typical)

2002 BRAKES Disc & Drum - Corolla

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. FRONT BRAKE CALIPER

Removal

Raise and support vehicle. Remove wheel and tire assembly. Disconnect brakeline from caliper. Plug brakeline to prevent fluid spillage. Remove caliper mounting bolts or slide pins if necessary. Remove caliper from torque plate. NOTE: Pushing piston into caliper bore forces fluid back into master cylinder reservoir. Remove reservoir cap when compressing piston.

Installation

Push piston into caliper bore, if necessary. DO NOT let piston dust boot wedge against edge of pads. To install, reverse removal procedure. Tighten bolts to specification. See TORQUE SPECIFICATIONS . Bleed brake system. See BLEEDING BRAKE SYSTEM . FRONT BRAKE ROTOR
Removal & Installation

1. Remove caliper assembly with brakeline connected, and wire aside. See FRONT BRAKE CALIPER . Remove torque plate from knuckle. 2. Mark rotor and hub for installation reference. Slide rotor off hub assembly. To install, reverse removal procedure. Tighten bolts to specification. See TORQUE SPECIFICATIONS . REAR BRAKE DRUM
Removal & Installation

Raise and support vehicle. Remove wheel and tire assembly. To remove drum, hold automatic adjuster lever away from adjuster and turn brake shoe adjuster to release shoes from drum. See Fig. 4 . To install reverse removal procedure. Check and adjust rear brake shoe clearance. See REAR BRAKE SHOES under ADJUSTMENTS.

2002 BRAKES Disc & Drum - Corolla

Fig. 4: Exploded View Of Rear Drum Brakes (Typical) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REAR DRUM BRAKE SHOES
Removal

1. Raise and support vehicle. Remove wheel and tire assembly. Remove brake drum. See REAR BRAKE DRUM . Disconnect return spring from front shoe. See Fig. 4 . Remove front shoe holddown spring, cup and pin. Remove anchor spring from front shoe, and remove front shoe. 2. Remove anchor spring from rear shoe. Remove rear shoe hold-down spring, cup and pin. Disconnect parking brake cable from lever. Remove rear shoe, adjuster and levers as an assembly. 3. Remove adjusting lever spring. Remove adjuster and return spring from rear shoe. Remove "C" washers, adjusting lever and parking brake lever from rear shoe.

2002 BRAKES Disc & Drum - Corolla

Installation

To install, reverse removal procedure. Apply high-temperature grease to adjuster components. Check and adjust rear brake shoe clearance. See REAR BRAKE SHOES under ADJUSTMENTS. Check and fill master cylinder reservoir. REAR WHEEL CYLINDER
Removal & Installation

With brake drum and shoes removed, disconnect brakeline from wheel cylinder. Remove mounting bolts and remove wheel cylinder. To install, reverse removal procedure. Check and adjust rear brake shoe clearance. See REAR BRAKE SHOES under ADJUSTMENTS. Bleed brake system. See BLEEDING BRAKE SYSTEM . MASTER CYLINDER
Removal

Disconnect level warning switch connector. Draw brake fluid from reservoir with a syringe. Disconnect and plug brake lines. On Corolla with ABS, disconnect ABS ECU connector. Remove 2 or 3-way bracket, if equipped. Remove master cylinder-to-power brake booster nuts. Remove master cylinder. See Fig. 5 or Fig. 6.
Installation

To install, reverse removal procedure. Tighten nuts to specification. See TORQUE SPECIFICATIONS . Check and adjust power brake unit push rod. See BRAKE BOOSTER PUSH ROD under ADJUSTMENTS. Bleed brake system. See BLEEDING BRAKE SYSTEM .

2002 BRAKES Disc & Drum - Corolla

Fig. 5: Exploded View Of Master Cylinder (Except ABS) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 6: Exploded View Of Master Cylinder (With ABS) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. BRAKE BOOSTER

2002 BRAKES Disc & Drum - Corolla

Removal

1. Remove master cylinder. See MASTER CYLINDER . Disconnect vacuum hose from brake booster. 2. Remove 2 nuts and cruise control ECU. Disconnect brakeline from flexible hose. Remove front left brakeline with grommet from body. Remove No. 1 panel and finish panel. 3. Remove pedal spring, clip, clevis pin, 4 nuts and clevis. Remove wave washer. Remove brake booster and gasket.
Installation

To install, reverse removal procedure. Use NEW gasket for mounting brake booster. Tighten nuts to specification. See TORQUE SPECIFICATIONS . Check and adjust push rod. See BRAKE BOOSTER PUSH ROD under ADJUSTMENTS.

OVERHAUL
NOTE: When overhauling caliper, if cylinder bores are pitted or scored beyond repair by light honing, replace entire assembly.

FRONT BRAKE CALIPER NOTE: Use illustration for exploded view of front brake caliper assembly. See Fig. 3.

REAR WHEEL CYLINDER NOTE: Use illustration for exploded view of rear wheel cylinder assembly. See Fig. 4.

MASTER CYLINDER NOTE: Use illustration for exploded view of master cylinder assembly. See Fig. 5 or Fig. 6 .

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS Application Brake Hose-To-Caliper Fitting Brakeline-To-Master Cylinder Fittings Brake Pedal Push Rod Lock Nut Caliper Installation Bolts Caliper Torque Plate Bolts Wheel Lug Nuts Bleed Screw Brake Booster Mounting Nuts Ft. Lbs. (N.m) 22 (30) 11 (15) 18 (24) 25 (34) 65 (88) 76 (103) INCH Lbs. (N.m) 73 (8.2) 115 (13)

2002 BRAKES Disc & Drum - Corolla

Master Cylinder Mounting Nuts Master Cylinder Reservoir Set Screw Master Cylinder Piston Stopper Bolt Parking Brake Adjustment Lock Nut Wheel Cylinder Mounting Bolts

115 (13) 15 (1.7) 89 (10) 48 (5.4) 89 (10)

DISC & DRUM BRAKE SPECIFICATIONS

DISC & DRUM BRAKE SPECIFICATIONS Application Front Disc Standard Disc Thickness Minimum Refinish Disc Thickness Maximum Disc Runout Standard Pad Thickness Minimum Pad Thickness Rear Brake Drum Brake Shoe-To-Drum Clearance Brake Shoe-To-Lever Side Clearance Standard Drum Diameter Maximum Refinish Drum Diameter Standard Lining Thickness Minimum Lining Thickness In. (mm) .866 (22.00) .787 (20.00) .002 (.05) .472 (12.00) .039 (1.00) .024 (.61) .014 (.35) 7.87 (200.0) 7.91 (201.0) .157 (3.98) .039 (1.00)

2002 EXTERIOR/INTERIOR TRIM Body - Corolla

2002 EXTERIOR/INTERIOR TRIM Body - Corolla

CLIP
REPLACEMENT The removal and installation methods of typical clips used in body parts are shown below. NOTE: If the clip is damaged during the operation, always replace it with a new clip.

2002 EXTERIOR/INTERIOR TRIM Body - Corolla

Fig. 1: Identifying Clip Installation & Removal Procedure (1 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 EXTERIOR/INTERIOR TRIM Body - Corolla

Fig. 2: Identifying Clip Installation & Removal Procedure (1 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

SRS AIRBAG
PRECAUTION The COROLLA is equipped with an SRS (Supplemental Restraint System) such as the driver AIRBAG, front passenger AIRBAG, side AIRBAG and set belt pretensioner. Failure to carry out service operation in the correct sequence could cause the SRS to unexpectedly deploy during servicing, possibly leading to a serious accident. Before servicing (including removal or installation of parts, inspection or replacement), be sure to read the precautionary notices. See AIR BAG SAFETY PRECAUTIONS .

FRONT BUMPER
COMPONENTS

2002 EXTERIOR/INTERIOR TRIM Body - Corolla

Fig. 3: Locating Front Bumper Components Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

REAR BUMPER
COMPONENTS

2002 EXTERIOR/INTERIOR TRIM Body - Corolla

Fig. 4: Locating Rear Bumper Components Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

HEADLIGHT
COMPONENTS

2002 EXTERIOR/INTERIOR TRIM Body - Corolla

Fig. 5: Locating Headlight Components Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL 1. Remove front bumper cover. See FRONT BUMPER . 2. Remove headlight : a. Remove the screw. b. Disconnect the connector, then remove the turn signal light. c. Remove the 2 bolts and nut.

2002 EXTERIOR/INTERIOR TRIM Body - Corolla

Fig. 6: Locating Headlight Mounting Bolts & Nut Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. d. Disconnect the connectors, then remove the headlight. e. Employ the same manner described above to the other side. INSTALLATION NOTE: At the time of installation, if the shown part of the headlight is damaged, the headlight can be reinstalled to the body by installing a bracket to it. See Fig. 7.

2002 EXTERIOR/INTERIOR TRIM Body - Corolla

Fig. 7: Identifying Substitutable Headlight Component Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Installation is in the reverse order of removal. See REMOVAL .

HOOD
ADJUSTMENT NOTE: Since the centering bolt is used as the hood hinge and lock set bolt, the hood and lock can not be adjusted with it on. Substitute a bolt and washer for the centering bolt.

2002 EXTERIOR/INTERIOR TRIM Body - Corolla

Fig. 8: Identifying Centering Bolt & Bolt With Washer For Substitution Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 1. Adjust hood in forward/rearward and left/right directions :

2002 EXTERIOR/INTERIOR TRIM Body - Corolla

Fig. 9: Identifying Hood Adjustment Directions Controlled By Top/Hood Side Of Hood Hinge Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Adjust the hood by loosening the hood side hinge bolts. Torque: 13 N.m (130 kgf.cm, 9 ft.lbf) 2. Adjust front edge of hood in vertical direction

2002 EXTERIOR/INTERIOR TRIM Body - Corolla

Fig. 10: Locating Vertical Hood Adjuster Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Adjust the hood by tuning the cushions. 3. Adjust hood lock :

2002 EXTERIOR/INTERIOR TRIM Body - Corolla

Fig. 11: Identifying Hood Lock Adjustment Directions Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Adjust the lock by loosening the bolts. Torque: 7.8 N.m (80 kgf.cm, 69 in. lbf)

FRONT DOOR
COMPONENTS

2002 EXTERIOR/INTERIOR TRIM Body - Corolla

Fig. 12: Locating Front Door Components Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. DISASSEMBLY NOTE: At the time of assembly, with door window fully closed, install the plate and the regulator handle with the snap ring.

2002 EXTERIOR/INTERIOR TRIM Body - Corolla

Fig. 13: Identifying Correct Window Regulator Handle Installation Position Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 EXTERIOR/INTERIOR TRIM Body - Corolla

Fig. 14: Removing Window Regulator Handle (W/O Power Window) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 1. W/O Power window, Remove regulator handle : Pull off the snap ring with a shop rag and remove the regulator handle and plate. 2. Remove door inside handle : a. Remove the screw and slide the handle forward.

2002 EXTERIOR/INTERIOR TRIM Body - Corolla

Fig. 15: Removing Door Handle (Inside Vehicle) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disconnect the handle from the control link and remove the handle. W/Power window, remove power window switch Remove armrest panel . Remove lower frame bracket garnish . Remove outside rear view mirror . Torque: 7.8 N-m (80 kgf.cm, 69 in..lbf) . 7. Remove front door trim : a. Remove the clip and 2 screws.

3. 4. 5. 6.

2002 EXTERIOR/INTERIOR TRIM Body - Corolla

Fig. 16: Locating Front Door Trim Clips & Mounting Screw Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 EXTERIOR/INTERIOR TRIM Body - Corolla

CAUTION: Be careful not to damage the door and door trim. Tape the screwdriver tip before use. b. Insert a screwdriver between the door and door trim to pry out. c. Pull the trim upwards to remove it. 8. Remove service hole cover : NOTE: At the time of assembly, do not block the grommet sealing with the cover.

a. Remove the 2 grommets. NOTE: At the time of assembly, bring out the link through the service hole cover.

b. Remove the service hole cover. 9. Remove outside rear view mirror : a. W/Power remote control mirror: Disconnect the connector. b. Remove the 3 nuts and mirror. 10. Remove door glass : a. Remove the hole plug. b. Remove the 2 bolts and door glass. Torque: 8.3 N.m (85 kgf.cm, 74 in. lbf) c. Remove the glass run. 11. Remove door belt moulding : a. Remove the clip. NOTE: Tape the scraper tip before use.

2002 EXTERIOR/INTERIOR TRIM Body - Corolla

Fig. 17: Exploded Side View Of Door Belt Moulding Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Using a scraper, remove the door belt moulding. 12. Remove service hole plate : Remove the 2 screws and plate. NOTE: At the time of assembly, using an air riveter, strike rivets into the door frame to install the speaker to the door frame.

2002 EXTERIOR/INTERIOR TRIM Body - Corolla

Fig. 18: Installing Speaker Rivets Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. If the rivet is not positioned perpendicularly it will bend the mandrel. When the trigger is then pulled, it may damage SST.

2002 EXTERIOR/INTERIOR TRIM Body - Corolla

Fig. 19: Identifying Mandrel & Example Of Incorrect Rivet Installation Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. CAUTION: The cut rivet and rivet cutter will be hot, avoid touching them. Do not jiggle the rivet cutter while cutting. You may enlarge the rivet hole or damage the rivet cutter. Do not drill the door inner hole. 13. Remove speaker : a. Using a drill of less then 0 4.8 mm (0.189 in.), drill out the rivet heads and remove the speaker.

2002 EXTERIOR/INTERIOR TRIM Body - Corolla

Fig. 20: Drilling Speaker Rivets Out Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Using a vacuum cleaner, remove the drilled rivet and the dust from the inside of the door. 14. Remove lower frame . NOTE: Remove the regulator through the service hole. At the time or assembly, apply MP grease to the window regulator. Do not apply grease to the spring of the window regulator.

2002 EXTERIOR/INTERIOR TRIM Body - Corolla

Fig. 21: Identifying Service Regulator MP Grease Application Points (Front Door) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 15. Remove window regulator : a. W/Power window, disconnect the connector. b. W/Power window, remove the 6 bolts and window regulator.

2002 EXTERIOR/INTERIOR TRIM Body - Corolla

Torque: 11.3 N.m (115 kgf.cm, 8 ft.lbf) c. W/O Power window, remove the 5 bolts and window regulator. Torque: 11.3 N.m (115 kgf.cm, 8 ft.lbf) 16. Remove door lock :

2002 EXTERIOR/INTERIOR TRIM Body - Corolla

2002 EXTERIOR/INTERIOR TRIM Body - Corolla

Fig. 22: Identifying Door Lock Mounting Bolts (Front Door) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. a. b. c. d. Remove the door lock control knob. Disconnect the control link from the door lock. Disconnect the links from the outside handle and key cylinder. W/Power door lock, disconnect the connector. NOTE: At the time of assembly, apply adhesive to 3 screws.

e. Remove the 3 screws. Torque: 4.9 N.m (50 kgf.cm, 43 in. lbf) Adhesive: Part No. 08833-00070, THREE BOND 1324 or equivalent. NOTE: At the time of assembly, apply MP grease to the sliding and rotating parts of the door lock.

Fig. 23: Identifying Door Lock MP Grease Application Points (Front Door) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 EXTERIOR/INTERIOR TRIM Body - Corolla

f. Remove the door lock through the service hole. 17. Remove outside handle : a. Remove the 2 bolts and outside handle with key cylinder. Torque: 5.4 N.m (55 kgf.cm, 47 in. lbf) b. Remove the bolt and key cylinder from the outside handle. ADJUSTMENT 1. Adjust door in forward/rearward and vertical directions : Using SST, adjust the door by loosening the body side hinge bolts.

Fig. 24: Identifying Door Adjustment Directions Controlled By Body Side Hinge (Front Door) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. SST 09812-00010 Torque: 25 N.m (260 kgf.cm, 19 ft.lbf) NOTE: Substitute the bolt with washer for the centering bolt. See Fig. 8 .

2002 EXTERIOR/INTERIOR TRIM Body - Corolla

Fig. 25: Identifying Door Adjustment Directions Controlled By Door Side Hinge (Front Door) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 2. Adjust door in left/right and vertical directions : Loosen the door side hinge bolts to adjust. Torque: 25 N.m (260 kgf.cm, 19 ft.lbf) 3. Adjust door lock striker : a. Check that the door fit and door lock linkages are adjusted correctly. b. Loosen the striker mounting screws to adjust. Torque: 23 N.m (230 kgf.cm, 17 ft.lbf) c. Using a plastic hammer, tap the striker to adjust it.

2002 EXTERIOR/INTERIOR TRIM Body - Corolla

Fig. 26: Adjusting Door Lock Striker Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REASSEMBLY Reassembly is in the reverse order of disassembly . See DISASSEMBLY .

REAR DOOR
COMPONENTS

2002 EXTERIOR/INTERIOR TRIM Body - Corolla

Fig. 27: Locating Rear Door Components Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. DISASSEMBLY NOTE: At the time of assembly, with door window fully closed, install the plate and the regulator handle with the snap ring.

2002 EXTERIOR/INTERIOR TRIM Body - Corolla

Fig. 28: Identifying Correct Window Regulator Handle Installation Position Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 EXTERIOR/INTERIOR TRIM Body - Corolla

Fig. 29: Removing Window Regulator Handle (W/O Power Window) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 1. W/O Power window, remove regulator handle . Pull off the snap ring with a shop rag and remove the regulator handle and plate. 2. Remove door inside handle : a. Remove the screw and slide the handle forward.

2002 EXTERIOR/INTERIOR TRIM Body - Corolla

Fig. 30: Removing Door Handle (Inside Vehicle) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disconnect the handle from the control link and remove the handle. 3. W/Power window, remove power window switch . . 4. Remove armrest panel . 5. Remove door trim : a. Remove the 2 screws and 2 clips.

2002 EXTERIOR/INTERIOR TRIM Body - Corolla

Fig. 31: Locating Rear Door Trim Clips & Mounting Screw Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. CAUTION: Be careful not to damage the door and door trim.

2002 EXTERIOR/INTERIOR TRIM Body - Corolla

Tape the screwdriver tip before use. b. Insert a screwdriver between the door and door trim to pry out. c. Pull the trim upward to remove it. NOTE: At the time of assembly, do not block the trim clip sealing with the service hole cover. Bring out the links through the service hole cover.

6. Remove service hole cover : Remove the 2 grommets and cover. 7. Remove door glass run . 8. Remove division bar : Remove the 3 screws and division bar.

2002 EXTERIOR/INTERIOR TRIM Body - Corolla

Fig. 32: Locating Division Bar Mounting Screws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 9. Remove door glass . 10. Remove door glass run . 11. Remove quarter window glass with weatherstrip . NOTE: Tape the scraper tip before use.

2002 EXTERIOR/INTERIOR TRIM Body - Corolla

Fig. 33: Locating Door Belt Moulding Clips Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 12. Remove door belt moulding : Using a scraper, remove the door belt moulding. NOTE: Remove the regulator through the service hole. At the time of assembly, apply MP grease to the window regulator. At the time of assembly, do not apply grease to the spring of the window regulator.

2002 EXTERIOR/INTERIOR TRIM Body - Corolla

Fig. 34: Locating Window Regulator MP Grease Application Points (Rear Door) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 13. Remove window regulator : a. W/Power window, disconnect the connector, then remove the 4 bolts and window regulator.

2002 EXTERIOR/INTERIOR TRIM Body - Corolla

Torque: 5.4 N.m (55 kgf.cm, 48 in. lbf) b. W/O Power window, remove the 3 bolts and window regulator. Torque: 5.4 N.m (55 kgf.cm, 48 in. lbf) NOTE: At the time of assembly, apply MP grease to the sliding and rotating parts of the door lock.

Fig. 35: Identifying Door Lock MP Grease Applications Points (Rear Door) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 EXTERIOR/INTERIOR TRIM Body - Corolla

Fig. 36: Locating Door Lock Mounting Bolts (Rear Door) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 14. Remove door lock :

2002 EXTERIOR/INTERIOR TRIM Body - Corolla

a. b. c. d. e. f. g.

Remove the door lock control knob from the link. Remove the door locking link guide. Using a clip remover, remove the bellcrank and clamp. Remove the links from the clamps. Remove the link from the outside handle. W/Power door lock, disconnect the connector. W/Power door lock, remove the bolt, 3 screws and door lock with control links. Torque: Screw: 4.9 N.m (50 kgf.cm, 43 in. lbf) NOTE: At the time of assembly, apply adhesive to the 3 screws.

h. W/O Power door lock, remove the 3 screws and door lock with control links. Torque: 4.9 N.m (50 kgf.cm, 43 in. lbf) . Adhesive : Part No. 08833-00700, THREE BOND 1324 or equivalent . 1. Remove the link protector and control links from the door lock. 2. Remove the silencer pad from the door panel. 15. Remove outside handle Torque: 5.4 N.m (55 kgf.cm, 47 in. lbf) ADJUSTMENT 1. Adjust door in forward/rearward and vertical directions : a. Remove front door scuff plate. b. Remove center pillar lower garnish. c. Remove the front seat bolt. See SEAT BELT PRETENSIONER . d. Loosen the body side hinge nuts to adjust.

2002 EXTERIOR/INTERIOR TRIM Body - Corolla

Fig. 37: Identifying Door Adjustment Directions Controlled By Body Side Hinge (Rear Door) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Torque: 25 N.m (260 kgf.cm, 19 ft.lbf) e. Install the removed parts. 2. Adjust door in left/right and vertical directions :

2002 EXTERIOR/INTERIOR TRIM Body - Corolla

Fig. 38: Identifying Door Adjustment Directions Controlled By Body Side Hinge (Rear Door) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Loosen the door side hinge bolts to adjust. Torque: 25 N.m (260 kgf.cm, 19 ft.lbf) 3. Adjust door lock striker : a. Check that the door fit and door lock linkages are adjusted correctly. b. Loosen the striker mounting screws to adjust. Torque: 23 N.m (230 kgf.cm, 17 ft.lbf) c. Using a plastic hammer, tap the striker to adjust it.

2002 EXTERIOR/INTERIOR TRIM Body - Corolla

Fig. 39: Adjusting Door Lock Striker Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REASSEMBLY Reassembly is in the reverse order of disassembly. See DISASSEMBLY .

LUGGAGE COMPARTMENT DOOR AND HINGE

COMPONENTS

2002 EXTERIOR/INTERIOR TRIM Body - Corolla

Fig. 40: Locating Luggage Compartment Door & Hinge Components Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL 1. Remove luggage compartment door : Remove the 4 bolts and door. Torque: 6.9 N.m (70 kgf.cm, 61 in. lbf)

2002 EXTERIOR/INTERIOR TRIM Body - Corolla

2. 3. 4. 5. 6. 7.

Remove luggage compartment mat . Remove rear floor finish plate . Remove rear floor finish side plate . Remove inner luggage compartment trim . Remove rear seat . See REMOVAL . Remove high-mounted stop light : a. Push on the both sides of the cover to release the claws by your hand and remove the cover.

Fig. 41: Locating High-Mounted Stop Light Clips & Identifying Removal Direction Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the stop light, then disconnect the connector. 8. Remove roof side inner garnish : NOTE: Tape the screwdriver tip before use.

2002 EXTERIOR/INTERIOR TRIM Body - Corolla

Fig. 42: Locating Roof Side Inner Garnish Clips Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. a. Using a screwdriver, remove the garnish. b. Employ the same manner described above to the other side. 9. Remove tether anchor : NOTE: Tape the screwdriver tip before use.

a. Using a screwdriver, remove the CRS tether anchor cover. b. Remove the tether anchor by loosening the bolt. c. Employ the same manner described above to the other sides. 10. Remove package tray trim . 11. Remove torsion bar : a. Install SST to the torsion bar on the hinge side. SST 09804-24010

2002 EXTERIOR/INTERIOR TRIM Body - Corolla

Fig. 43: Removing Torsion Bar (1 Of 3) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Push down SST, and pull the luggage compartment door hinge from the torsion bar.

2002 EXTERIOR/INTERIOR TRIM Body - Corolla

Fig. 44: Removing Torsion Bar (2 Of 3) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Slowly lift SST, and remove the torsion bar from the torsion bar bracket with SST.

2002 EXTERIOR/INTERIOR TRIM Body - Corolla

Fig. 45: Removing Torsion Bar (3 Of 3) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. d. Disconnect the torsion bar from the bracket. e. Employ the same manner described above to the other side. 12. Remove luggage compartment door hinges : Remove the 2 pins and hinges. DISASSEMBLY 1. Remove door lock : a. Disconnect the control link. b. Remove the 2 bolts and lock.

2002 EXTERIOR/INTERIOR TRIM Body - Corolla

Torque: 4.9 N.m (50 kgf.cm, 43 in. lbf) . c. Remove the 2 clips and luggage compartment door inside handle cover.

Fig. 46: Locating Luggage Compartment Door Handle Mounting Clips (Inside Handle) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE: Tape the screwdriver tip before use.

2002 EXTERIOR/INTERIOR TRIM Body - Corolla

d. Using a screwdriver remove the luggage compartment door inside handle. 2. Remove door combination light : a. Disconnect the connector. b. Remove the nuts and rear combination lights. 3. Remove door lock cylinder : Remove the retainer and lock cylinder. ADJUSTMENT 1. Adjust luggage compartment door : a. For forward/rearward and left/right adjustments loosen the bolts. Torque: 6.9 N.m (70 kgf.cm, 61 in. lbf) b. For vertical adjustment of the front end of the door, increase or decrease the number of washers between the hinge and the door.

Fig. 47: Identifying Adjustment Directions Controlled By Luggage Compartment Door Mounting Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 2. Adjust door lock striker :

2002 EXTERIOR/INTERIOR TRIM Body - Corolla

a. Remove the rear floor finish plate by pulling. b. Remove the clips and the rear luggage trim. c. Loosen the bolts to adjust.

Fig. 48: Identifying Adjustment Directions Controlled By Luggage Compartment Door Lock Striker Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Torque: 4.9 N.m (50 kgf.cm, 43 in. lbf) REASSEMBLY Reassembly is in the reverse order of disassembly. See DISASSEMBLY . INSTALLATION Installation is in the reverse order of removal. See REMOVAL .

2002 EXTERIOR/INTERIOR TRIM Body - Corolla

FRONT WIPER AND WASHER

COMPONENTS

Fig. 49: Locating Front Wiper And Washer Components Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL 1. 2. 3. 4. Remove wiper arms . Remove hood to cowl top seal . Remove cowl louver . Remove wiper motor assembly : a. Disconnect the connector. b. Unfasten the 4 bolts and remove the wiper motor assembly.

2002 EXTERIOR/INTERIOR TRIM Body - Corolla

Fig. 50: Locating Wiper Motor Mounting Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 5. Remove wiper link assembly : Remove the 6 bolts and wiper link. 6. Remove window washer nozzle : a. Remove the hose from the nozzle. NOTE: Tape the screwdriver tip before use.

2002 EXTERIOR/INTERIOR TRIM Body - Corolla

Fig. 51: Unclipping Window Washer Nozzle Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Using a screwdriver, remove the nozzle. c. Employ the same manner described above to the other side. INSPECTION
Inspect Washer Nozzle

NOTE:

Letters of lists correspond to window washer fluid coverage areas identified in figures.

For USA, see Fig. 52 . For CANADA, see Fig. 53 .

2002 EXTERIOR/INTERIOR TRIM Body - Corolla

. a. While operating the washer, check that the washer fluid hits the windshield and the upsurge area within the shaded areas. USA

Fig. 52: Identifying Window Washer Fluid Coverage Areas (USA) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. A. B. C. D. E. F. G. H. I. Approx. 150 mm (5.91 in.) . Approx. 50 mm (1.97 In.) . Approx. 0-50 mm (0 - 5.91 in.) . Approx. 415 mm (16.34 in.) . Approx. 210 mm (8.28 in.) . Approx. 220 mm (8.66 in.) . Approx. 250 mm (9.84 in.) . Approx. 260 mm (10.24 in.) . Approx. 365 mm (14.37 in.) .

2002 EXTERIOR/INTERIOR TRIM Body - Corolla

CANADA

Fig. 53: Identifying Window Washer Fluid Coverage Areas (CANADA) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. A. Approx. 150 mm (5.91 in.) . B. Approx. 0-50 mm (0 - 5.91 in.) . C. Approx. 190 mm (7.48 in.) . D. Approx. 450 mm (17.72 in.) . E. Approx. 165 mm (6.50 in.) . F. Approx. 465 mm (18.31 in.) . G. Approx. 210 mm (8.27 in.) . H. Approx. 80 mm (3.15 in.) . I. Approx. 55 mm (2.17 in.) . J. Approx. 300 mm (11.81 in.) . K. Approx. 490 mm (19.29 in.) . b. Check if the lower point where the washer fluid hits the windshield is within the range of the wiping pattern (the area of the glass which the wiper blades wipe).

2002 EXTERIOR/INTERIOR TRIM Body - Corolla

ADJUSTMENT
Adjust Washer Nozzle

Rotate the nozzle to adjust the fluid direction against the windshield. Tool Dimension A: USA: 0.7 - 0.75 mm (0.028 - 0.0295 in.) CANADA: 0.55 - 0.6 mm (0.0217 - 0.024 in.) Tool Dimension B: . 2.0 - 2.5 mm (0.079 - 0.098 in.)

Fig. 54: Identifying Nozzle Adjustment Tool Dimensions For A & B Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSTALLATION 1. Install window washer nozzles . 2. Install wiper link assembly : Install the wiper link with the 6 bolts. Torque: 5.4 N.m (55 kgf.cm, 48 in. lbf) . 3. Install wiper motor assembly :

2002 EXTERIOR/INTERIOR TRIM Body - Corolla

a. Fasten the 4 bolts and install the wiper motor assembly. Torque: 5.4 N.m (55 kgf.cm, 48 in. lbf) . b. Connect the connector. 4. Install cowl louver . 5. Install hood to cowl top seal . 6. Install wiper arms : a. Install the wiper arms and tighten nuts by hand. Operate the wipers once and turn the wiper switch OFF. b. Adjust the installation positions of the wiper arms to the proper positioin.

Fig. 55: Identifying Proper Position Of Wiper Arms Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. A: 25.0 + 15.0 mm (0.984 + 0.591 in.) . c. Torque the nuts. Torque: 20 N.m (205 kgf.cm, 15 ft.lbf) .

BODY OUTSIDE MOULDING

COMPONENTS

2002 EXTERIOR/INTERIOR TRIM Body - Corolla

Fig. 56: Identifying Body Outside Moulding Components Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL NOTE: Do not heat moulding excessively.

1. Heat moulding : Using a heat light, heat the moulding to 40 - 60C (104 - 140F). CAUTION:

If reusing the moulding, take care not to damage the moulding. Do not damage the body.

2. Remove moulding : a. Tie both piano wire ends to a wooden block or a similar object. b. Cut the adhesive tape by pulling the piano wire.

2002 EXTERIOR/INTERIOR TRIM Body - Corolla

Fig. 57: Identifying Molding Removal Procedure Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Remove the moulding. INSTALLATION 1. Clean body mounting surface : NOTE: Do not heat body excessively.

a. Using a heat light, heat the body mounting surface to 40 -60C(104-140F). b. Remove protective tape from the body. c. Wipe off stains with cleaner. 2. Clean moulding (if reusing the moulding). NOTE: Do not heat moulding excessively.

a. Using a heat light, heat the moulding to 20 - 30C (68 -86F). b. Remove the adhesive tape from the moulding.

2002 EXTERIOR/INTERIOR TRIM Body - Corolla

c. Wipe off stains with cleaner. d. Apply a new adhesive tape to moulding.

Fig. 58: Identifying Adhesive Tape Application Points Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 3. Install moulding :

Fig. 59: Installing Moulding Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE: Do not heat moulding excessively.

a. Using a heat light, heat the body and moulding. Body: 40 - 60C (104 - 140F)

2002 EXTERIOR/INTERIOR TRIM Body - Corolla

Moulding: 20 - 30C (68 - 86F) NOTE:

When the moulding release sheet is removed, make sure that no dirt or dust can get onto the uncoated area. Do not apply excessive force onto the moulding, but steady pressure with your thumbs.

b. Lift moulding release sheet from the face of moulding.

ROOF DRIP SIDE FINISH MOULDING

COMPONENTS

Fig. 60: Identifying Roof Drip Side Finish Moulding Components Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL 1. Remove roof drip side finish moulding : Using SST, pull off the roof drip moulding from the front ends. SST 09806-30010

2002 EXTERIOR/INTERIOR TRIM Body - Corolla

Fig. 61: Removing & Exploded View Of Roof Drip Side Finish Moulding Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 2. Remove rear roof drip side finish moulding :

2002 EXTERIOR/INTERIOR TRIM Body - Corolla

Fig. 62: Locating Rear Roof Drip Side Finish Moulding Clips Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Using a clip remover, remove the moulding. INSTALLATION 1. Install rear roof drip side finish moulding . 2. Install roof drip side finish moulding : Attach the upper edge of the moulding to the body flange. Tap on the moulding by hand.

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Fig. 63: Installing Roof Drip Side Finish Moulding Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

ROCKER PANEL MOULDING

COMPONENTS

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Fig. 64: Identifying Rocker Panel Moulding Components Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL
Remove Rocker Panel Moulding

a. Remove the 2 screws and 6 clips.

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Fig. 65: Locating Rocker Panel Moulding Clips & Screws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE: Tape the screwdriver tip before use.

b. Using a screwdriver, remove the rocker panel moulding. INSTALLATION Installation is in the reverse order of removal. See REMOVAL .

WINDSHIELD
COMPONENTS

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Fig. 66: Identifying Windshield Components Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL 1. 2. 3. 4. Remove inner rear view mirror . Remove sun visors and holders . W/Sliding roof, remove map light . Remove front pillar garnish : a. Pry out clips by your hand.

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Fig. 67: Locating Front Pillar Garnish Clips Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Pull the garnish upward to remove it. c. Employ the same manner described above to the other side. Remove wiper arms . Remove hood to cowl top seal . Remove cowl louver . Remove assist grip . W/Sliding roof, remove sliding roof opening trim . Remove roof headlining front side . CAUTION: Do not damage the body with the knife.

5. 6. 7. 8. 9. 10.

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Fig. 68: Identifying Windshield Moulding Cut Line Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 11. Remove windshield moulding : Using a knife, cut off the moulding. CAUTION: When separating the glass, be careful not to damage the paint and interior and exterior ornaments. To prevent scratching the safety pad when removing the windshield, place a plastic sheet between the piano wire and safety pad. 12. Remove windshield glass : a. Push piano wire through between the body and glass from the interior.

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Fig. 69: Using Piano Wire To Separate Windshield From Vehicle (1 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE: Apply adhesive tape to the outer surface to keep the surface from being scratched.

b. Tie both wire ends to a wooden block or a similar object. NOTE: Leave as much of the adhesive on the body as possible when removing the glass.

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Fig. 70: Using Piano Wire To Separate Windshield From Vehicle (2 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Cut the adhesive by pulling the piano wire around it. d. Remove the glass. INSTALLATION 1. Clean and shape contact surface of body : a. Using a knife, cut away any rough areas on the body. NOTE: Leave as much of the adhesive on the body as possible.

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Fig. 71: Reshaping Adhesive Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE: Even if all the adhesive has been removed, clean the body.

b. Clean the cutting surface of the adhesive with a shop rag saturated in cleaner. 2. Replace stopper : a. Remove the damaged stopper. CAUTION: Be careful not to damage the body.

b. Cut off the old adhesive around the stopper installation area. c. Clean the installation area. d. Install a new stopper onto the glass.

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Fig. 72: Locating Windshield Stoppers & Identifying Stopper Dimensions Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 3. Clean removed glass : a. Using a scraper, remove the adhesive sticking to the glass.

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Fig. 73: Identifying Glass Cleaning Techniques Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Clean the glass with cleaner. NOTE: Do not touch the glass after cleaning it.

4. Replace dam : a. Remove the damaged dam. b. Clean the installation area. c. Install a new dam with double-stick tape. See Fig. 74 . NOTE: Do not touch the glass face after cleaning it.

A. 7.0 mm (0.276 in.) B. 16.3 mm (0.642 in.)

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Fig. 74: Identifying Application Points & Dimensions Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 5. Position glass : a. Place glass in the correct position.

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Fig. 75: Placing Reference Marks & Inspecting Windshield Placement Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Cheek that all contacting parts of the glass rim are perfectly even. c. Place reference marks between the glass and body. d. Remove the glass. NOTE: Do not touch the glass face after cleaning it.

6. Clean contact surface of glass : Using a cleaner, clean the contact surface which black-colored area around the entire glass rim. 7. Coat contact surface of body with primer "M" : Using a brush, coat the contact surface on the body with Primer M. NOTE:

Let the primer coating dry for 3 minutes or more. Do not coat Primer M to the adhesive. Do not keep any of the opened Primer "M" for later use.

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Fig. 76: Identifying Correct Application Of Primer "M" Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 8. Coat contact surface of glass with primer "G" : a. Using a brush or a sponge, coat the edge of the glass and the contact surface with Primer G. b. Before the primer dries, wipe it off with a clean shop rag. NOTE:

Let the primer coating dry for 3 minutes or more. Do not keep any of the opened Primer G for later use.

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Fig. 77: Identifying Correct Application Of Primer "G" Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 9. Apply adhesive : NOTE: After cutting off the tip, use all adhesive within the time described in the table.

Fig. 78: Ambient Temperature To Time Of Adhesive Use Table Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. a. Cut off the tip of the cartridge nozzle. Adhesive:

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Part No. 08850-00801 or equivalent b. Load the cartridge into the sealer gun. c. Coat the glass with adhesive as shown. A. 12.5 mm (0.492 in.) B. 8.0 mm (0.315 in.)

Fig. 79: Identifying Proper Glass Adhesive Application & Illustration Of Dimensions A & B Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 10. Install glass : NOTE: Confirm that the dam is attached to the body panel as shown. See Fig. 80 .

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Fig. 80: Identifying Proper Attachment Of Dam Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. a. Position the glass so that the reference marks are lined up, and press in gently along the rim.

Fig. 81: Realigning Reference Marks Placed On Windshield Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

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b. Using a spatula, apply adhesive on the glass rim. c. Use a scraper to remove any excessive or protruding adhesive.

Fig. 82: Scraping Excessive/Protruding Adhesive Off Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. d. Hold the glass in place securely with a protective tape or equivalent until the adhesive hardens. NOTE: Take care not to drive the vehicle during the time described in Fig. 83 .

Fig. 83: Windshield Installation To Safe Vehicle Operation Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 11. Inspect for leak and repair : a. Do a leak test after the hardening time has elapsed.

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b. Seal any leak with sealant. Sealant: Part No. 08833-00030 or equivalent 12. Apply adhesive at moulding installation area : Coat the glass with adhesive at the moulding installation area.

Fig. 84: Applying Moulding Adhesive Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Part No. 08833-00030 or equivalent 13. Install windshield moulding : Place a new moulding onto the body and tap it by hand.

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Fig. 85: Identifying Correct Installation Of Windshield Moulding Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 14. 15. 16. 17. 18. 19. Install roof headlining front side . W/Sliding roof, Install sliding roof opening trim Install assist grip . Install cowl louver . Install hood to cowl top seal . Install wiper arms : a. Install the wiper arms and tighten nuts by hand. Operate the wipers once and turn the wiper switch OFF. b. Adjust the installation positions of the wiper arms to the proper positions.

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Fig. 86: Identifying Proper Position Of Wiper Arms Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. A: 25.0 + 15.0 mm (0.984 + 0.591 in.) c. Torque the nuts. Torque: 20 N.m (205 kgf.cm, 15 ft.lbf) 20. 21. 22. 23. Install front pillar garnishes . W/Sliding roof, install map light Install sun visors and holders . Install inner rear view mirror .

BACK WINDOW GLASS

COMPONENTS

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Fig. 87: Identifying Back Window Glass Components Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL 1. Remove rear seat . See REMOVAL . 2. Remove high-mounted stop light . a. Push on the both sides of the cover to release the claws by your hand and remove the cover.

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Fig. 88: Locating High-Mounted Stop Light Clips & Identifying Removal Direction Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the stop light, then disconnect the connector. 3. Remove roof side inner garnish : a. Using a screwdriver, pry loose and remove the garnish. NOTE: Tape the screwdriver tip before use.

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Fig. 89: Locating Roof Side Inner Garnish Clips Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Employ the same manner described above to the other side. 4. Remove tether anchor : a. Using a screwdriver, remove the CRS tether anchor cover. NOTE: Tape the screwdriver tip before use.

b. Remove the tether anchor by loosening the bolt. c. Employ the same manner described above to the other sides. 5. Remove package tray trip . 6. Disconnect defogger wire connectors . NOTE: Do not damage the body with the knife.

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Fig. 90: Identifying Back Window Moulding Cut Line Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 7. Remove back window moulding . Using a knife, cut off the moulding.

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8. Remove back window glass : Remove the glass in the same way as windshield. See REMOVAL . INSTALLATION During back glass installation, the procedures follow those for windshield installation and are marked with references to the windshield installation steps used in the windshield installation procedure. Refer to INSTALLATION , and install the back window glass by the following operations. 1. Clean and shape contact surface of body . 2. Replace stopper . Refer to step 2 under WINDSHIELD INSTALLATION. a. Remove the damaged stoppers. b. Cut off the old adhesive around the stopper installation area. c. Clean the installation area. d. Install new stoppers on the glass.

Fig. 91: Locating Stoppers Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 3. Clean removed glass . Refer to step 3 under WINDSHIELD INSTALLATION. 4. Clean contact surface of glass . Refer to step 6 under WINDSHIELD INSTALLATION. 5. Coat contact surface of body with primer "M" . Refer to step 7 under WINDSHIELD INSTALLATION.

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6. Coat contact surface of glass with primer "G" . Refer to step8 under WINDSHIELD INSTALLATION. 7. Apply adhesive . Refer to step 9 under WINDSHIELD INSTALLATION. 8. Install back window glass . Refer to step 10 under WINDSHIELD INSTALLATION. 9. Inspect for leak and repair . a. Do a leak test after the hardening time has elapsed. b. Seal any leak with sealant. Refer to step 11 under WINDSHIELD INSTALLATION. Sealant: Part No. 08833-00030 or equivalent 10. Apply adhesive at moulding installation area . Refer to step 12 under WINDSHIELD INSTALLATION. 11. Install back window moulding . Refer to step 13 under WINDSHIELD INSTALLATION. 12. Connect defogger wire connectors . 13. Install package tray trim . 14. Install tether anchor . a. Install the tether anchor by tightening the bolt. b. Install the CRS tether anchor cover to the tether anchor. c. Employ the same manner described above to the other sides. 15. Install roof side inner garnishes : 16. W/High-mounted stop light, install high-mounted stop light

Fig. 92: Locating High-Mounted Stop Light Clips & Identifying Removal Direction Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

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a. Connect the connector, then install the stop light. b. Push on both sides of the cover to engage the claws by hand and install the cover. 17. Install rear seat. See INSTALLATION .

SLIDING ROOF
ON-VEHICLE INSPECTION
Inspect Sliding Roof Glass Alignment

Fig. 93: Identifying Correct Sliding Roof Alignment Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. a. Start the engine and check the operation time of the sliding roof. Operation time: Approx. 6 sec. b. Check for abnormal noise or binding during operation. c. With the sliding roof fully closed, check for water leakage. d. Check for a difference in level between the sliding roof weatherstrip and roof panel. Except rear end: 0 +/- 1.5 mm (0 +/- 0.059 in.) Rear end:

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0 + 1.5 mm (0 + 0.059 in.) 0-1.0 mm (0 - 0.039 in.) COMPONENTS

Fig. 94: Identifying Sliding Roof Components Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL

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1. Remove roof headlining. See REMOVAL . 2. Remove sliding roof glass assembly : a. Using a torx wrench, remove the 4 screws. b. Pull the glass upward to remove it. NOTE: At the time of installation, if the sliding roof position and drive gear full close position are not matched, the sliding roof does not operate normally. Remove the drive gear with the sliding roof fully closed.

NOTE:

3. Remove drive gear : a. Disconnect the connector. b. Remove the 3 bolts and drive gear.

Fig. 95: Locating Drive Gear & Mounting Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Remove the screw and cam plate cover. d. Turn the drive gear to align the point marks.

2002 EXTERIOR/INTERIOR TRIM Body - Corolla

2002 EXTERIOR/INTERIOR TRIM Body - Corolla

Fig. 96: Aligning Point Marks Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. e. Install the cam plate cover and screw. 4. Remove sliding roof housing : a. Disconnect the 4 drain hoses from the housing. b. Remove the 8 torx screws and 4 brackets.

Fig. 97: Locating Brackets, Torx Screws & Bolts Called Out In Step 4 Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Remove the 6 nuts, then remove the housing. DISASSEMBLY 1. Remove sliding roof panel stopper : Remove the 2 screws and 2 stoppers. 2. Remove sunshade trim :

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Fig. 98: Locating Sunshade Trim Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 3. Remove rear roof drip channel : Remove the rear roof drip channel.

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Fig. 99: Removing Rear Roof Drip Channel Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE: At the time of reassembly, please refer to following items.

Adjust the drive cable to a closed and tilted down position. Slide the cable forward or backward to align the 2 marks.

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Fig. 100: Locating Cable Alignment Marks Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Slide the cable to the forefront with your hand.

4. Remove drive cable : a. Remove the screw and guide rail stopper.

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Fig. 101: Drive Cable Removal Procedure Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Slide the drive cable rearward, then remove it. 5. Remove roof window deflector panel : 6. Remove guide block : Remove the 2 screws and guide block.

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Fig. 102: Locating Guide Block Mounting Screws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 7. Remove sliding roof housing : Remove the 6 screws and sliding roof housing.

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Fig. 103: Locating Sliding Roof Housing Mounting Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ADJUSTMENT 1. To adjust forward or rearward : a. Using a torx wrench, loosen the sliding roof glass installation screws. b. Adjust the sliding roof glass forward and rearward. 2. Difference in left and right clearance: To adjust clearance : a. When the front or rear alignment is not correct, remove the drive gear and sliding roof glass, then adjust the drive rail. NOTE: Remove the drive gear with sliding roof fully closed.

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Fig. 104: Identifying Misalignment & Proper Alignment Of Sliding Roof Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Adjust by sliding the cable forward or rearward to align the 2 marks.

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Fig. 105: Locating Cable Alignment Marks Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Install the drive gear and sliding roof glass. REASSEMBLY Reassembly is in the reverse order of disassembly. See DISASSEMBLY . INSTALLATION Installation is in the reverse order of removal. See REMOVAL .

INSTRUMENT PANEL
COMPONENTS

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Fig. 106: Locating Instrument Panel Components (1 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

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Fig. 107: Locating Instrument Panel Components (2 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE: Screw shapes and sizes are indicated in Fig. 108 . The codes (A - H) correspond to those indicated in Fig. 106 and Fig. 107 .

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Fig. 108: Screw Identification & Sizing Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL 1. Remove front door scuff plates . 2. Remove cowl side trims . 3. Remove front pillar garnish : a. Pry out clips by your hand.

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Fig. 109: Locating Front Pillar Garnish Clips Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Pull the garnish upward to remove it. c. Employ the same manner described above to the other side. 4. Remove steering wheel . See STEERING COLUMN . 5. Remove lower finish panel : a. Remove the 2 bolts and panel.

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Fig. 110: Locating Lower Finish Panel Mounting Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disconnect the hood lock control cable. 6. Remove lower insert : Remove the 2 bolts and lower insert. 7. Remove cluster finish panel : a. Remove the 2 screws. NOTE: Tape the screwdriver tip before use.

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Fig. 111: Locating Cluster Finish Panel Clips & Mounting Screws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Using a screwdriver, remove the cluster finish panel. Remove steering column cover . See STEERING COLUMN . Remove combination switch . Remove No. 2 heater to register duct . Remove combination meter . Remove steering column assembly . See STEERING COLUMN . Remove lower panel : Remove the 2 bolts, 3 screws and lower panel.

8. 9. 10. 11. 12. 13.

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Fig. 112: Locating Lower Panel Mounting Bolts & Screws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 14. Disconnect AIRBAG connector : CAUTION: When handling the AIRBAG connector, take care not to damage the AIRBAG wire harness. a. Remove the AIRBAG connector from the front passenger AIRBAG assembly. b. Disconnect the AIRBAG connector.

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Fig. 113: locating AIRBAG connector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 15. Remove front passenger AIRBAG assembly : NOTE: At the time of installation, please refer to the following items:

Make sure that the front passenger AIRBAG assembly is installed to the specified torque. If the front passenger AIRBAG assembly has been dropped, or there are cracks, dents or other defects in the case or connector, replace the front passenger - AIRBAG assembly with a new one. When installing the front passenger AIRBAG assembly, take care that the wiring does not interfere with other parts and is not pinched between other parts.

a. Remove the 2 bolts and 2 nuts. Torque: Bolt: 20 N.m (205 kgf.cm, 15 ft.lbf) WARNING:

Do not store the front passenger AIRBAG assembly with the AIRBAG deployment side facing down. Never disassemble the front passenger AIRBAG

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assembly.

Fig. 114: Locating Front Passenger AIRBAG & Mounting Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the front passenger AIRBAG assembly from the instrument panel. 16. Remove lower LH panel : Remove the bolt and panel. 17. Remove lower RH panel : Remove the bolt and panel. 18. 19. 20. 21. M/T, remove shifting hole knob . M/T, remove shifting hole cover . A/T, remove shifting hole bezel . Remove rear console box . Remove the 2 bolts, 2 screws and rear console box. NOTE: Tape the screwdriver tip before use.

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22. Remove center lower cluster finish panel : Using a screwdriver, remove the center lower cluster finish panel, then disconnect the connector. 23. Remove stereo opening cover . 24. Remove lower center finish panel : Remove the 2 screws and lower center finish panel.

Fig. 115: Locating Lower Center Finish Panel Clips Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 25. Remove A/C control panel. See REMOVAL . 26. Remove center cluster finish panel : NOTE: Tape the screwdriver tip before use.

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Fig. 116: Locating Center Cluster Finish Panel Clips Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. a. Using a screwdriver, remove the center cluster finish panel. b. Remove the radio assembly. 27. Remove instrument panel : a. Disconnect the connectors. b. Remove the 4 screws and instrument panel.

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Fig. 117: Locating Instrument Panel Mounting Screws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 28. Remove heater to register duct : Remove the screw and heater to register duct. 29. Remove lower defroster nozzle . 30. Remove No. 1 brace : Remove the bolt, 2 nuts and No. 1 brace. 31. Remove No. 2 brace : Remove the bolt, nut and No. 2 brace. 32. Remove reinforcement : Remove the 3 bolts, 4 nuts and reinforcement. 33. Remove lower instrument panel cowl brace : Remove the bolt, nut and lower instrument panel cowl brace.

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DISASSEMBLY 1. Remove defroster nozzle : Remove the 3 screws and defroster nozzle. 2. Remove No. 1 heater to register duct : Remove the 2 screws and No. 1 heater to register duct. 3. Remove cluster finish panel sub-assembly . 4. Remove center bracket : Remove the 3 screws and center bracket. 5. Remove meter mounting bracket : Remove the screw and meter mounting bracket. 6. Remove safety pad : Remove the 8 screws and safety pad. 7. Remove wire harness . REASSEMBLY Reassembly is in the reverse order of disassembly. See DISASSEMBLY . INSTALLATION Installation is in the reverse order of removal. See REMOVAL .

ROOF HEADLINING
COMPONENTS

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Fig. 118: Identifying Roof Headlining Components Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL 1. 2. 3. 4. 5. Remove rear seat . See REMOVAL . Remove inner rear view mirror . Remove front door scuff plates . Remove cowl side trims . Remove center pillar lower garnishes .

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6. 7. 8. 9.

Remove rear door scuff plates . Remove front door opening trims . Remove rear door opening trims . Remove front pillar garnish . a. Pry out clips by your hand.

Fig. 119: Locating Front Pillar Garnish Clips Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Pull the garnish upward to remove it. c. Employ the same manner described above to the other side. 10. Remove center pillar upper garnish : a. Remove the front seat outer belt shoulder anchor. Torque: 41 N.m (420 kgf.cm, 30 ft.lbf) b. Remove the center pillar upper garnish.

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Fig. 120: Locating Center Pillar Upper Garnish Clip Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Employ the same manner described above to the other side. 11. W/High-mounted stop light, remove high-mounted stop light . a. Push on the both sides of the cover to release the claws by your hand and remove the cover.

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Fig. 121: Locating High-Mounted Stop Light Clips & Identifying Removal Direction Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the stop light, then disconnect the connector. 12. Remove roof side inner garnish : NOTE: Tape the screwdriver tip before use.

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Fig. 122: Locating Roof Side Inner Garnish Clips Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. a. Using a screwdriver, pry loose and remove the garnish. b. Employ the same manner described above to the other side. 13. Remove tether anchor : a. Using a screwdriver, remove the CRS tether anchor cover. NOTE: Tape the screwdriver tip before use.

b. Remove the tether anchor by loosening the bolt. c. Employ the same manner described above to the other sides. 14. Remove package tray trim . 15. Remove room light : a. Using a screwdriver, remove the room light cover. NOTE: Tape the screwdriver tip before use.

b. Remove the 3 screws, then disconnect the connector.

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Fig. 123: Locating Room Light, Cover & Mounting Screws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 16. 17. 18. 19. W/Sliding roof, remove map light assembly . W/Sliding roof, remove sliding roof opening trim . Remove sun visors and holders . Remove assist grips .

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20. Remove roof headlining : a. Remove the 3 clips from the roof panel rear end. b. Remove the headlining. c. Bring out the headlining.

Fig. 124: Locating Roof Panel Clips (Rear End) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSTALLATION Installation is in the reverse order of removal. See REMOVAL .

FRONT SEAT
COMPONENTS

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Fig. 125: Locating Front Seat Components Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL Remove front seat : a. Using a screwdriver, remove the seat track covers. NOTE: Tape the screwdriver tip before use.

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b. Remove the 4 bolts. c. W/Side AIRBAG assembly, disconnect the connector. d. Remove the front seat. NOTE: Be careful not to damage the body.

DISASSEMBLY 1. 2. 3. 4. Remove headrest . Remove reclining adjuster release handle . Remove front seat cushion shield . Remove inner front seat cushion cover . Remove the screw and inner front seat cushion cover. 5. Remove front seat inner belt . Remove the bolt and front seat inner belt. 6. Remove seatback assembly . a. W/Side AIRBAG assembly, remove side AIRBAG wire harness from wire harness protector.

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Fig. 126: Locating Side AIRBAG Wire Harness Protector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the hog rings. c. Remove the 4 bolts and seatback assembly. 7. Remove seatback cover : a. W/Side AIRBAG assembly, Remove the hook from the seatback frame.

2002 EXTERIOR/INTERIOR TRIM Body - Corolla

Fig. 127: Locating Seatback Frame Hook (W/Side AIRBAG) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the headrest supports. c. Remove the seatback frame from the seatback cover with pad. d. Remove the seatback cover from the seatback pad. 8. Remove seat cushion assembly Remove the 4 bolts and seat cushion assembly from the seat adjuster. 9. Remove seat cushion cover : a. Remove the hog rings and seat cushion frame. b. Remove the hog rings and seat cushion cover from the seat cushion pad. 10. Remove reclining connecting pipe : Remove the reclining connecting pipe. 11. Remove seat track handle : Remove the seat track handle. INSPECTION

2002 EXTERIOR/INTERIOR TRIM Body - Corolla

Inspect reclining lock position and sliding lock position slipping off NOTE: When the reclining lock positions slip off, disassemble the seat to adjust the position.

a. When reclining the seat, inspect that the outer and inner recliners are released at the same time. NOTE: When sliding lock positions slip off, loosen the bolts to adjust the position.

b. When sliding the seat, inspect that the outer and inner tracks are locked at the same time. REASSEMBLY 1. Install seat track handle : Install the seat track handle. NOTE: When installing the connecting pipe with raising up the adjusters, the lock positions adjusted in 2-(a) step slip off then lock error will occur.

2. Install reclining connecting pipe : a. Adjust the reclining lock positions of the seat adjusters. b. Slide the seat adjusters to the most front position. c. Place the adjusters on a spacer to adjust the seat rails in parallel and install the connecting pipe.

2002 EXTERIOR/INTERIOR TRIM Body - Corolla

Fig. 128: Identifying Spacer Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 3. Install seat cushion cover : a. Install the seat cushion cover with new hog rings to seat cushion pad. NOTE: Install the hog rings to prevent wrinkles as least as possible.

b. Install the seat cushion cover with pad to the seat cushion frame with new hog rings. NOTE: Tighten the 4 bolts temporarily, then from the bolts on the rear side tighten them completely.

4. Install seat cushion assembly : Install the seat cushion assembly with the 4 bolts to the seat adjuster. Torque: 21 N.m (210 kgf.cm, 15 ft.lbf) 5. Install seatback cover : a. Install the seatback cover with new hog rings to the seat-back pad. b. Install the seatback cover with pad to the seatback frame with new hog rings.

2002 EXTERIOR/INTERIOR TRIM Body - Corolla

c. Install the headrest supports. d. W/Side AIRBAG assembly, hang the hook onto the seatback frame.

Fig. 129: Locating Seatback Frame Hook (W/Side Airbag) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. CAUTION: Take care to hung the hook securely. Otherwise the seat cover slides, it might cause incorrect deploying. 6. Install seatback assembly : a. Install the seatback assembly with 4 bolts. NOTE: Tighten the 4 bolts temporarily, then from the bolt on the front right side tighten them completely.

Torque: 43 N.m (440 kgf.cm, 32 ft.lbf) NOTE: Install the hog rings to prevent wrinkles as least as possible.

b. Install new hog rings. c. W/Side AIRBAG assembly, securely fix the side AIRBAG wire harness to seat cushion with

2002 EXTERIOR/INTERIOR TRIM Body - Corolla

the wire harness protector.

Fig. 130: Locating Side AIRBAG Wire Harness Protector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 7. Install front seat inner belt : Install the front seat inner belt with the bolt. Torque: 41 N.m (420 kgf.cm, 30 ft.lbf) 8. Install inner front seat cushion cover : Install the inner front seat cushion cover with the screw. 9. Install front seat cushion shield . 10. Install reclining adjuster release handle . 11. Install headrest . INSTALLATION Install front seat :

2002 EXTERIOR/INTERIOR TRIM Body - Corolla

a. Slide the front seat to the most front position. NOTE: NOTE: Make sure that seat adjuster locks. If holding the seat track handle, the adjusted most front positions slip off.

b. Without holding the seat track handle, mount the seat to the vehicle. c. Tighten the bolts on the rear side temporarily, from the bolt on the inner side tighten them completely. Torque: 37 N.m (375 kgf.cm, 27 ft.lbf) d. Slide the seat to the most rear position to install the bolts on the front side. Torque: 37 N.m (375 kgf.cm, 27 ft.lbf) e. W/Side AIRBAG assembly, connect the connector. f. Install the seat track covers.

REAR SEAT (SPLIT TYPE)

COMPONENTS

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Fig. 131: Locating Split Type Rear Seat Components (1 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

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Fig. 132: Locating Split Type Rear Seat Components (2 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL

2002 EXTERIOR/INTERIOR TRIM Body - Corolla

1. Remove seat cushion assembly : a. Remove the seat cushion assembly. b. Remove the 2 lock hooks. 2. Remove LH seatback assembly : a. Release lock to lean the seatback to front. b. Remove the 2 bolts and the LH seatback assembly. 3. W/CRS, Remove child restraint seat a. Remove the child restraint seat cover. b. Remove the 4 bolts. c. Remove the child restraint seat. 4. W/O CRS, remove RH seatback assembly a. Release lock to lean the seatback to front. b. Remove the 2 bolts and the RH seatback assembly. 5. W/CRS, remove RH seatback assembly Remove the 3 bolts and the RH seatback assembly. 6. Remove seatback hinge : a. Remove the 2 bolts and LH seatback hinge. b. Remove the 2 bolts and center seatback hinge. c. Remove the 2 bolts and RH seatback hinge. DISASSEMBLY 1. Remove seat cushion cover : Remove the hog rings and seat cushion cover from the seat cushion pad. 2. Turn over seatback cover : Remove the clips, and turn over the seatback cover. Remove headrest . Remove headrest supports . Remove seatback lock knob . Remove seatback lock knob cover . Remove seatback cover : a. Remove the hog rings and seatback frame from the seatback cover with pad. b. Remove the hog rings and seatback cover from the seatback pad. 8. Remove seatback lock : a. Remove the rear lock control cable. b. Remove the 2 bolts and rear seatback lock control. REASSEMBLY 3. 4. 5. 6. 7.

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Reassembly is in the reverse order of disassembly. See DISASSEMBLY . INSTALLATION Installation is in the reverse order of removal. See REMOVAL .

REAR SEAT (FIXED TYPE)

COMPONENTS

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Fig. 133: Locating Fixed Type Rear Seat Components Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL 1. Remove seat cushion assembly : a. Remove the seat cushion assembly. NOTE: Remove the rear seat inner with center belt from seat cushion slit to remove the seat cushion.

b. Remove the 2 lock hooks. 2. Remove seatback assembly : Remove the 3 bolts and the seatback assembly. DISASSEMBLY 1. Remove seat cushion cover : Remove the hog rings and seat cushion cover from the seat cushion pad. 2. Remove seatback cover : a. W/Headrest, remove the 2 headrests. b. W/Headrest, remove the 4 headrest supports. c. Remove the hog rings and seatback cover from the seatback pad. REASSEMBLY Reassembly is in the reverse order of disassembly. See DISASSEMBLY . INSTALLATION Installation as In the reverse order of removal. See REMOVAL .

SEAT BELT
COMPONENTS

2002 EXTERIOR/INTERIOR TRIM Body - Corolla

Fig. 134: Locating Seat Belt Components (1 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

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Fig. 135: Locating Seat Belt Components (2 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSPECTION CAUTION: Replace the seat belt assembly (outer belt, inner belt, bolts, nuts) if it

2002 EXTERIOR/INTERIOR TRIM Body - Corolla

has been used in a severe impact. The entire assembly should be replaced even if damage is not obvious. 1. Except manual type, Running test (in safe area) a. Fasten the front seat belts. b. Drive the car at 10 mph (16 km/h) and slam on the brakes. Check that the belt locks and cannot be extended at this time. CAUTION: Conduct this test in a safe area. If the belt does not lock, remove the belt mechanism assembly and conduct the following static check. Also, whenever installing a new belt assembly, verify the proper operation before installation. 2. Driver's seat belt (ELR): Static test a. Make sure that the belt locks when pulled out quickly. b. Remove the locking retractor assembly. c. Tilt the retractor slowly. d. Make sure that the belt can be pulled out at a tilt of 15 degrees or less, and cannot be pulled out over 45 degrees of tilt.

Fig. 136: Measuring Seat Belt Tilt Angle

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Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. If a problem is found, replace the assembly. NOTE: Ensure that more than 300 mm (11.81 in.) of belt is extracted with installed on the vehicle. If a problem is found, replace the assembly. 3. Except driver's seat belt (ALR/ELR): Static Test a. Make sure that the belt locks when pulled out quickly. NOTE: Ensure that more than 200 mm (7.87 in.) of rear seat belt is retracted with installed on the vehicle.

b. Remove the locking retractor assembly. c. Pull out the whole belt and measure the length of the whole belt. Then retract the belt slightly and pull it out again. d. Make sure that the belt cannot be extended further. If a problem is found, replace the assembly. e. Retract the whole belt, then pull out the belt until 200 mm (7.87 in.) of belt remains retracted.

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Fig. 137: Measuring Seat Belt Retraction Length Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. f. Tilt the retractor slowly. g. Make sure that the belt can be pulled out at a tilt of 15 degrees or less, and cannot be pulled out at over 45 degrees of tilt.

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Fig. 138: Measuring Seat Belt Tilt Angle Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

SEAT BELT PRETENSIONER

REMOVAL NOTE:

If the wiring connector of the seat belt pretensioner is disconnected with the ignition switch at ON or ACC, diagnostic trouble codes will be recorded. Never use seat belt pretensioner from another vehicle. When replacing parts, replace them with new parts.

1. Remove front door scuff plate 2. Remove center pillar lower garnish 3. Remove front seat outer belt a. Remove the bolt and front seat outer belt floor anchor. b. Using a screwdriver, remove the shoulder anchor caps. NOTE: Tape the screwdriver tip before use.

c. Remove the bolt and front seat outer belt shoulder anchor.

2002 EXTERIOR/INTERIOR TRIM Body - Corolla

Fig. 139: Locating Outer Belt Shoulder Anchor (Front Seat) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 4. Remove retractor of front seat outer belt : CAUTION: Never disassemble the front seat outer belt.

NOTE:

When removing the front seat outer belt, take care not to pull the seat belt pretensioner wire harness.

a. LH side only:

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Disconnect the retractor switch connector. CAUTION: When removing the seat belt pretensioner, work must be started 90 seconds after the ignition switch is turned to the "LOCK" position and the negative (-) cable is disconnected from the battery.

Fig. 140: Locating Pretensioner Connector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disconnect the pretensioner connector. c. Remove the 2 bolts and retractor of the front seat outer belt. INSPECTION 1. Pretensioner is not activated a. Perform a diagnostic system check. See AIR BAG RESTRAINT SYSTEMS . b. Perform a visual check which includes the following items with the front seat outer belt removed from the vehicle. NOTE: For removal and installation of the front seat outer belt, see SEAT BELT . Be sure to follow the correct procedure.

2002 EXTERIOR/INTERIOR TRIM Body - Corolla

Fig. 141: Seat Belt Pretensioner Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Check for cuts and cracks in, or marked discoloration of the center pillar lower garnish. Check for cuts and cracks in wire harness, and for chipping in connectors. Check for deformation of the center pillar. 2. Pretensioner is activated :

2002 EXTERIOR/INTERIOR TRIM Body - Corolla

a. Perform a diagnostic system check. See AIR BAG RESTRAINT SYSTEMS . b. Perform a visual check which includes the following item with the front seat outer belt removed from the vehicle. Check for deformation of the center pillar.

Fig. 142: Identifying Center Pillar & Wire Harness Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Check for damage to the connector and wire harness.

DISPOSAL NOTE: When scrapping vehicle equipped with an SRS or disposing of a front seat outer belt (with seat belt pretensioner), always first deploy the AIRBAG in accordance with the procedure given in AIR BAG RESTRAINT SYSTEMS . If any abnormality occurs with the AIRBAG deployment or seat belt pretensioner activation, contact the SERVICE DEPARTMENT of TOYOTA MOTOR SALES, USA INC. When disposing of a front seat outer belt (with seat belt pretensioner) activated in a collision, follow the same procedure given in step 1 (c ).

2002 EXTERIOR/INTERIOR TRIM Body - Corolla

CAUTION:

Never dispose of front seat outer belt which has inactivated pretens The seat belt pretensioner produces a sizeable exploding sound wh activates, so perform the operation out-of-door and where it will not create a nuisance to nearby residents. When activating the seat belt pretensioner, always use the specified (SRS AIRBAG Deployment Tool). Perform the operation in a place a from electrical noise.

Fig. 143: Identifying SRS Deployment Tool Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. SST 09082-00700, 09082-00740

When activating a front seat outer belt (with seat belt pretensioner), perform the operation at least 10 m (33 ft) away from the front seat o belt. Use gloves and safety glasses when handling a front seat outer bel activated pretensioner. Always wash your hands with water after completing the operation. Do not apply water, etc. to a front seat outer belt with activated pretensioner.

1. Seat Belt Pretensioner Deployment When Scrapping Vehicle :

2002 EXTERIOR/INTERIOR TRIM Body - Corolla

NOTE:

Have a battery ready as the power source to activate the seat belt pretensioner.

Fig. 144: Powering SRS Deployment Tool Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. a. Check functioning of SST. SST 09082-00700, 09082-00740 CAUTION: When activating the seat belt pretensioner, always use the specified SST: SRS AIRBAG Deployment Tool.

2002 EXTERIOR/INTERIOR TRIM Body - Corolla

Fig. 145: Identifying SRS Deployment Tool Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 1. Connect the SST to battery. NOTE: Do not connect the yellow connector which will be connected with the seat belt pretensioner.

2002 EXTERIOR/INTERIOR TRIM Body - Corolla

Fig. 146: Powering SRS Deployment Tool Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Connect the red clip of the SST to the battery positive (+) terminal and the black clip to the battery negative (-) terminal. 2. Check functioning of SST. CAUTION: If the LED lights up when the activation switch is not being pressed, SST malfunction is probable, so definitely do not use the SST. Press the SST activation switch, and check the LED of the SST activation switch lights up.

2002 EXTERIOR/INTERIOR TRIM Body - Corolla

Fig. 147: Locating SRS Deployment Tool Activation Switch Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disconnect the pretensioner connector. 1. Remove the front door scuff plate. 2. Remove the center pillar lower garnish. 3. Disconnect the pretensioner connector.

2002 EXTERIOR/INTERIOR TRIM Body - Corolla

Fig. 148: Locating Pretensioner Connector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Install the SST. 1. Buckle the front seat belt and check that there is no looseness and slack in the front seat inner belt and front seat outer belt. CAUTION: To avoid damaging the SST connector and wire harness, do not lock secondary lock of the twin lock.

2002 EXTERIOR/INTERIOR TRIM Body - Corolla

Fig. 149: Connecting SST's To Seat Belt Pretensioner Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 2. Connect the 2 SSTs to each other, then connect them to the seat belt pretensioner. SST 09082-00700, 09082-00740 3. Move the SST to at least 10mm (33 ft) from the front of the vehicle. CAUTION: Take care not to damage the SST wire harness.

4. Close all the doors and windows of the vehicle. 5. Connect the SST red clip to the battery positive (-) terminal and the black clip to the negative (+) terminal. d. Activate seat belt pretensioner. 1. Confirm that no one is inside the vehicle or within 10 m (33 ft) area around the vehicle. NOTE: The seat belt pretensioner operates simultaneously as the LED of the SST activation switch lights up.

2. Press the SST activation switch and activate the seat belt pretensioner.

2002 EXTERIOR/INTERIOR TRIM Body - Corolla

e. Dispose of the front seat outer belt (with seat belt pretensioner).

Fig. 150: Measuring SRS Deployment Tool To Vehicle Distance Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. CAUTION:

The front seat outer belt is very hot when the seat belt pretensioner is activated, so leave it alone for at least 30 minutes after activation. Use gloves and safety glasses when handling a front seat outer belt with activated seat belt pretensioner. Always wash your hands with water after completing the operation. Do not apply water, etc. to a front seat outer belt with activated seat belt pretensioner.

NOTE:

When scrapping a vehicle, activate the seat belt pretensioner and scrap the vehicle with activated front seat outer belt still installed.

2. Activation when disposing of front seat outer belt only NOTE:

When disposing of the front seat outer belt (with seat belt pretensioner)

2002 EXTERIOR/INTERIOR TRIM Body - Corolla

only, never use the customer's vehicle to activate the seat belt pretensioner. Be sure to follow the procedure given below when activating the seat belt pretensioner.

NOTE:

Have a battery ready as the power source to activate the seat belt pretensioner.

a. Remove the front seat outer belt. See SEAT BELT . NOTE: Cut the belt near the seat belt retractor.

b. Check functioning of SST. See step 1-( ). SST 09082-00700, 09082-00740

Fig. 151: Powering SRS Deployment Tool Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 EXTERIOR/INTERIOR TRIM Body - Corolla

c. Install the SST. 1. Connect the 2 SSTs to each other, then connect them to the seat belt pretensioner. CAUTION: To avoid damaging the SST connector and wire harness, do not lock the secondary lock of the twin lock.

Fig. 152: Connecting SST's To Seat Belt Pretensioner Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. SST 09082-00700, 09082-00740 NOTE: Place the front seat outer belt. See Fig. 153 .

2002 EXTERIOR/INTERIOR TRIM Body - Corolla

Fig. 153: Placing Front Seat Outer Belt Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 2. Locate the front seat outer belt on the ground and cover it with the disc wheel with tire. NOTE: Take care not to damage the SST wire harness.

3. Move the SST to at least 10 m (33 ft) from the disc wheel. d. Activate the seat belt pretensioner. 1. Connect the SST red clip to the battery positive (+) terminal and black clip to the battery negative (-) terminal. 2. Check that no one is within 10 m (33 ft) area around the disc wheel.

2002 EXTERIOR/INTERIOR TRIM Body - Corolla

Fig. 154: Identifying Safety Distance SST To SRS Deployment Tool/Nearest Person Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE: The seat belt pretensioner operates simultaneously as the LED of the SST activation switch lights up.

3. Press the SST activation switch and activate the seat belt pretensioner. e. Dispose of the front seat outer belt (with seat belt pretensioner). CAUTION:

The front seat outer belt is very hot when the seat belt pretensioner is activated, so leave it alone for at least 30 minutes after activation. Use gloves and safety glasses when handling a front seat outer belt with activated seat belt pretensioner. Always wash your hands with water after completing the operation. Do not apply water, etc. to a front seat outer belt with activated seat belt pretensioner.

1. Remove the disc wheel and SST. 2. Place the front seat outer belt in a vinyl bag, tie the end tightly and dispose of it in the same way as other general parts.

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Fig. 155: Disposing Of Front Seat Outer Belt Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REPLACEMENT
Replace Requirements

2002 EXTERIOR/INTERIOR TRIM Body - Corolla

In the following cases, replace the seat belt pretensioner.

If the seat belt pretensioner has been activated. If the seat belt pretensioner has been found to be faulty in troubleshooting. If the front seat outer belt has been found to be faulty during the check in items 1-(b) or 2-(b). If the front seat outer belt has been dropped. CAUTION: For removal and installation of the seat belt pretensioner, see SEAT BELT PRETENSIONER and INSTALLATION . Be sure to follow the correct procedure.

INSTALLATION NOTE:

Never use seat belt pretensioner from another vehicle. When replacing parts, replace them with new parts. Make sure that the front seat outer belt is installed to the specified torque. If the front seat outer belt has been dropped, or there are cracks, dents or other defects in the case or connector, replace the front seat outer belt with a new one. When installing the front seat outer belt, take care that the wiring does not interfere with other parts and is not pinched between other parts.

1. Install retractor of front seat outer belt a. Install retractor of front seat outer belt with the 2 bolts. Torque: Upper bolt: 4.9 N.m (50 kgf.cm, 43 in. lbf) Lower bolt: 41 N.m (420 kgf.cm, 30 ft.lbf) b. Connect the pretensioner connector. See Fig. 156 .

2002 EXTERIOR/INTERIOR TRIM Body - Corolla

Fig. 156: Locating Pretensioner Connector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. LH side only: Connect the retractor switch connector. 2. Install front seat outer belt a. Install the front seat outer belt shoulder anchor with the bolt. Torque: 41 N.m (420 kgf.cm, 30 ft.lbf) b. Install the shoulder anchor cap. c. Install the front seat outer belt floor anchor with the bolt. Torque: 41 N.m (420 kgf.cm, 30 ft.lbf) . 3. Install center pillar lower garnish . 4. Install front door scuff plate .

2002 ELECTRICAL Generators & Regulators - Corolla

2002 ELECTRICAL Generators & Regulators - Corolla

CHARGING SYSTEM
ON-VEHICLE INSPECTION CAUTION:

Check that the battery cables are connected to the correct terminals. Disconnect the battery cables when the battery is given a quick charge. Do not perform tests with a high voltage insulation resistance tester. Never disconnect the battery while the engine is running.

1. Check Battery Electrolyte Level Check the electrolyte quantity of each cell. Maintenance-free Battery: If under the lower level, replace the battery (or add distilled water if possible) and check the charging system. Except Maintenance-free Battery: If under the lower level, add distilled water. 2. Except Maintenance-Free Battery: Check Battery Specific Gravity Check the specific gravity of each cell. Standard Specific Gravity: 1.25 - 1.29 at 20C (68F) If the specific gravity is less than specification, charge the battery.

2002 ELECTRICAL Generators & Regulators - Corolla

Fig. 1: Checking Battery Specific Gravity Of Cells Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 3. Maintenance-Free Battery: Check Battery Voltage a. After having driven the vehicle and in the case that 20 minutes have not passed after having stopped the engine, turn the ignition switch ON and turn on the electrical system (headlight, blower motor, rear defogger etc.) for 60 seconds to remove the surface charge. b. Turn the ignition switch OFF and turn off the electrical systems. c. Measure the battery voltage between the negative (-) and positive (+) terminals of the battery. Standard Voltage: 12.5 - 12.9 V At 20C (68F) If the voltage is less than specification, charge the battery. 4. Check Battery Terminals, Fusible Link And Fuses a. Check that the battery terminals are not loose or corroded. b. Check the fusible link, H-fuses and fuses for continuity.

2002 ELECTRICAL Generators & Regulators - Corolla

Fig. 2: Checking Battery Voltage Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 5. Inspect Drive Belt a. Visually check the belt for excessive wear, frayed cords etc. If any defects has been found, replace the drive belt. NOTE:

Cracks on the rib side of a belt are considered acceptable. If the belt chunks missing from the ribs, it should be replaced.

2002 ELECTRICAL Generators & Regulators - Corolla

Fig. 3: Checking Drive Belt Wear Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. The drive belt tension can be released by turning the belt tensioner clockwise.

2002 ELECTRICAL Generators & Regulators - Corolla

Fig. 4: Displaying How To Release Drive Belt Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Check the belt tensioner operation. Check that belt tensioner moves downward when the drive belt is pressed down at the points indicated in the illustration with approx. 98 N (10 kgf, 22.0 lbf) of force. Check the alighment of the belt tensioner pulley to make sure the drive belt will not slip off the pulley. If necessary, replace the belt tensioner.

2002 ELECTRICAL Generators & Regulators - Corolla

Fig. 5: Checking Belt Tensioner Operation Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

After installing a belt, check that it fits properly in the ribbed grooves. Check with your hand to confirm that the belt has not slipped out of the groove onthe bottom of the pulley. After installing a new belts, run the engine for about 5 minutes and check the belt tension existing.

6. Visually Check Generator Wiring And Listen For Abnormal Noises a. Check that the wiring is in good condition. b. Check that there is no abnormal noise from the generator while the engine is running. 7. Inspect Discharge Warning Light Circuit a. Turn the ignition switch "ON". Check that the discharge warning light comes on. b. Start the engine. Check that the light goes off. If the light does not operate as specified, troubleshoot the discharge warning light circuit.

2002 ELECTRICAL Generators & Regulators - Corolla

Fig. 6: Checking Correct Installation Of Belt Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 8. Inspect Charging Circuit Without Load NOTE: If a battery/generator tester is available, connect the tester to the charging circuit as permanufacturer's instructions. a. If a tester is not available, connect a voltmeter to the charging circuit as follows: Disconnect to the wire from terminal B of the generator and connect it to the negative (-) lead of the ammeter. Connect the positive (+) lead of the ammeter to terminal B of the generator. Connect the positive (+) lead of the voltmeter to terminal B of the generator. Ground the negative (-) lead of the voltmeter.

2002 ELECTRICAL Generators & Regulators - Corolla

Fig. 7: Connecting Voltmeter To Charging Circuit Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Check the charging circuit as follows: With the engine running from idle to 2,000 rpm, check the reading on the ammeter and voltmeter. Standard Amperage: 10 A or less Standard Voltage: 13.5 - 15.1 V If the voltmeter reading is more than standard voltage, replace the voltage regulator. If the voltmeter reading is less than the standard voltage, check the voltage regulator. See INSPECTION . 9. Inspect Charging Circuit With Load a. With the engine running at 2,000 rpm, turn on the high beam headlights and place the heater blower switch at "H". b. Check the reading on the ammeter. Standard Amperage: 30 A Or More If the ammeter reading is less than standard amperage, repair the generator.

2002 ELECTRICAL Generators & Regulators - Corolla

NOTE:

If the battery is fully charged, the indication will sometimes be less than standard amperage.

GENERATOR
COMPONENTS

2002 ELECTRICAL Generators & Regulators - Corolla

Fig. 8: Displaying Generator Components (1 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 9: Displaying Generator Components (2 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL 1. Remove Drive Belt Turn the drive belt tensioner slowly clockwise and loosen it. Then, remove the drive belt and replace the drive belt tensioner little by little and fix it quietly.

2002 ELECTRICAL Generators & Regulators - Corolla

Fig. 10: Removing Drive Belt Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 2. Remove Generator a. Disconnect the wire clamp from the wire clip on the rectifier end frame. b. Remove the rubber cap and nut, and disconnect the generator wire. c. Disconnect the generator connector.

2002 ELECTRICAL Generators & Regulators - Corolla

Fig. 11: Disconnecting Wire Clamp Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 3. Remove the 2 bolts and generator.

2002 ELECTRICAL Generators & Regulators - Corolla

Fig. 12: Removing Bolts & Generator Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. DISASSEMBLY 1. Remove Rear End Cover a. Remove the nut and terminal insulator. b. Remove the bolt, 3 nuts, plate terminal, end cover and brush holder cover.

2002 ELECTRICAL Generators & Regulators - Corolla

Fig. 13: Removing Rear End Cover Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 2. Remove Brush Holder And Voltage Regulator a. Remove the 5 screws, brush holder and voltage regulator. b. Remove the seal plate from the rectifier end frame.

2002 ELECTRICAL Generators & Regulators - Corolla

Fig. 14: Locating Screws For Brush Holder & Voltage Regulator Removal Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 3. Remove Rectifier Holder a. Remove the 4 screws and rectifier holder. b. Remove the 4 rubber insulators.

2002 ELECTRICAL Generators & Regulators - Corolla

Fig. 15: Locating Screw For Rectifier Holder Removal Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 4. Remove Pulley a. Hold SST (A) with a torque wrench, and tighten SST (B) clockwise to the specified torque. SST 09820-63011 Torque: 39 N.m (400 kgf.cm, 29 ft.lbf) b. Check that SST (A) is secured to the rotor shaft.

2002 ELECTRICAL Generators & Regulators - Corolla

Fig. 16: Displaying Pulley Removal Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Mount SST (C) in a vise. d. Insert SST (B) into SST (C), and attach the pulley nut to SST (C).

2002 ELECTRICAL Generators & Regulators - Corolla

Fig. 17: Displaying SST (B) & SST (C) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. e. To loosen the pulley nut, turn SST (A) in the direction shown in the illustration. NOTE: To prevent damage to the rotor shaft, do not loosen the pulley nut more than one-half of a turn.

f. Remove the generator from SST (C).

2002 ELECTRICAL Generators & Regulators - Corolla

Fig. 18: Loosening Pulley Nut Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. g. Turn SST (B), and remove SST (A and B). h. Remove the pulley nut and pulley.

2002 ELECTRICAL Generators & Regulators - Corolla

Fig. 19: Displaying SST (A & B) Removal Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 5. Remove Rectifier End Frame a. Remove the 4 nuts and wire clip.

2002 ELECTRICAL Generators & Regulators - Corolla

Fig. 20: Displaying Wire Clip Removal Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Using SST, remove the rectifier end frame. SST 09286-46011 c. Remove the generator washer from the rotor 6. Remove Rotor From Drive End Frame

2002 ELECTRICAL Generators & Regulators - Corolla

Fig. 21: Removing Rectifier End Frame Using SST Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSPECTION 1. Inspect Voltage Regulator a. Using an ohmmeter, check the continuity between terminals F and B. Standard: When The Positive And Negative Poles Between Terminals F And B Are Exchanged, There Is Continuity In One Way But No Continuity In Another Way. If the continuity is not as specified, replace the regulator.

2002 ELECTRICAL Generators & Regulators - Corolla

Fig. 22: Checking Continuity Between Terminals F & B Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 2. Using an ohmmeter, check the continuity between terminals F and E. Standard: When The Positive And Negative Poles Between Terminals F And E Are Exchanged, There Is Continuity Is One Way But No Continuity In Another Way. If the continuity is not as specified, replace the regulator.

2002 ELECTRICAL Generators & Regulators - Corolla

Fig. 23: Checking Continuity Between Terminals F & E Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 3. Inspect Rotor a. Check the rotor for open circuit. Using an ohmmeter, check that there is continuity between the slip rings. Standard Resistance: 2.7 - 3.1 ohm At 20C (68F) If there is no continuity, replace the rotor.

2002 ELECTRICAL Generators & Regulators - Corolla

Fig. 24: Checking Continuity Between Slip Springs Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Check the rotor for ground. Using an ohmmeter, check that there is no continuity between the slip ring and rotor. If there is continuity, replace the rotor. c. Check that the slip rings are not rough or scored. If rough or scored, replace the rotor.

2002 ELECTRICAL Generators & Regulators - Corolla

Fig. 25: Inspecting Rotor For Ground Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. d. Using a vernier caliper, measure the slip ring diameter. Standard Diameter: 14.2 - 14.4 mm (0.559 - 0.567 in.) Minimum Diameter: 12.8 mm (0.504 in.) If the diameter is less than minimum, replace the rotor.

2002 ELECTRICAL Generators & Regulators - Corolla

Fig. 26: Measuring Slip Ring Diameter Using Vernier Caliper Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 4. Inspect Stator (Drive End Frame) a. Check the stator for open circuit. Using an ohmmeter, check that there is continuity between the coil leads. If there is no continuity, replace the drive end frame assembly

2002 ELECTRICAL Generators & Regulators - Corolla

Fig. 27: Checking Continuity Between Coil Leads Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Check the stator for ground. Using an ohmmeter, check that there is no continuity between the coil lead and drive end frame. If there is continuity, replace the drive end frame assembly.

2002 ELECTRICAL Generators & Regulators - Corolla

Fig. 28: Checking For No Continuity Between Coil Lead & Drive End Frame Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 5. Inspect Brush Using vernier calipers, measure the exposed brush length. Standard Exposed Length: 9.5 - 11.5 mm (0.374 - 0.453 in.) Minimum Exposed Length: 1.5 mm (0.059 in.) If the exposed length is less than minimum, replace the brush holder assembly.

2002 ELECTRICAL Generators & Regulators - Corolla

Fig. 29: Measuring Exposed Brush Length Using Vernier Caliper Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 6. Inspect Rectifiers (Rectifire Holder) a. Check the positive (+) rectifire. 1. Using an ohmmeter, connect one tester probe to the positive (+) terminal and the other to each rectifier terminal. 2. Reverse the polarity of the tester probes and repeat step (a). 3. Check that one shows continuity and the other shows no continuity. If continuity is not as specified, replace the rectifier holder.

2002 ELECTRICAL Generators & Regulators - Corolla

Fig. 30: Inspecting Positive Rectifier Holder Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Check the negative (-) rectifier. 1. Using an ohmmeter, connect one tester probe to each negative (-) terminal and the other to each rectifier terminal. 2. Reverse the polarity of the tester probes and repeat step (a). 3. Check that one shows continuity and the other shows no continuity. If continuity is not as specified, replace the rectifier holder.

2002 ELECTRICAL Generators & Regulators - Corolla

Fig. 31: Inspecting Negative Rectifier Holder Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Inspect Bearing Check that the bearing is not rough or worn. If necessary, replace the bearing (See page CH12). REPLACEMENT 1. Replace Front Bearing a. Remove the 4 screws and retainer.

2002 ELECTRICAL Generators & Regulators - Corolla

Fig. 32: Locating Screws For Front Bearing Replacement Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Using a socket wrench and press, press out the bearing.

2002 ELECTRICAL Generators & Regulators - Corolla

Fig. 33: Pressing Bearing Out Using Socket Wrench Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Using SST and a press, press in a new bearing. SST 09950-60010 (09951-00500) d. Insall the retainer with the 4 screws. Torque: 3.0 N.m (31 kgf.cm, 27 in..lbf)

2002 ELECTRICAL Generators & Regulators - Corolla

Fig. 34: Pressing New Bearing Using SST Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 2. Replace Rear Bearing a. Using SST, remove the bearing cover (outside) and bearing. SST 09820-00021 NOTE: Be careful not to damage the fan.

2002 ELECTRICAL Generators & Regulators - Corolla

Fig. 35: Displaying Bearing Cover Removal (Outside) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the bearing cover (inside). c. Place the bearing cover (inside) on the rotor.

2002 ELECTRICAL Generators & Regulators - Corolla

Fig. 36: Locating Bearing Cover (Inside) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. d. Using SST and a press, press in a new bearing. SST 09820-00031

2002 ELECTRICAL Generators & Regulators - Corolla

Fig. 37: Pressing In New Bearing Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. e. Using SST, push in the bearing cover (outside). SST 09285-76010

2002 ELECTRICAL Generators & Regulators - Corolla

Fig. 38: Pushing In Bearing Cover (Outside) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REASSEMBLY 1. Install Rotor To Drive End Frame a. Place the rectifier end frame on the pulley. b. Install the rotor to the rectifier end frame.

2002 ELECTRICAL Generators & Regulators - Corolla

Fig. 39: Installing Rotor To Drive End Frame Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 2. Install Rectifier End Frame a. Place the generator washer on the rotor.

2002 ELECTRICAL Generators & Regulators - Corolla

Fig. 40: Placing Generator Washer On Rotor Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Using a 29 mm socket wrench and press, slowly press in the rectifier end frame.

2002 ELECTRICAL Generators & Regulators - Corolla

Fig. 41: Pressing In Rectifier End Frame Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Install the wire clip and 4 nuts. Torque: 4.5 N.m (46 kgf.cm, 40 in..lbf) for nut A 5.4 N.m (55 kgf.cm, 48 in..lbf) for nut B

2002 ELECTRICAL Generators & Regulators - Corolla

Fig. 42: Installing Wire Clip & Nuts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 3. Install Pulley a. Install the pulley to the rotor shaft by tightening the pulley nut by hand. b. Hold SST (A) with a torque wrench, and tighten SST (B) clockwise to the specified torque. SST 09820-63011 Torque: 39 N.m (400 kgf.cm, 29 ft.lbf) c. Check that SST (A) is secured to the pulley shaft.

2002 ELECTRICAL Generators & Regulators - Corolla

Fig. 43: Installing Pulley To Rotor Shaft Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. d. Mount SST (C) in a vise. e. Insert SST (B) into SST (C), and attach the pulley nut to SST (C).

2002 ELECTRICAL Generators & Regulators - Corolla

Fig. 44: Locating SST (C) For Attachment Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. f. To torque the pulley nut, turn SST (A) in the direction shown. Torque: 110.5 N.m (1,125 kgf.cm, 81 ft.lbf) g. Remove the generator from SST (C).

2002 ELECTRICAL Generators & Regulators - Corolla

Fig. 45: Displaying How To Remove Generator Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. h. Turn SST (B), and remove SST (A and B).

2002 ELECTRICAL Generators & Regulators - Corolla

Fig. 46: Removing SST (A & B) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 4. Install Rectifier Holder a. Install the 4 rubber insulator on the lead wires. NOTE: Be careful of the rubber insulators installation direction.

2002 ELECTRICAL Generators & Regulators - Corolla

Fig. 47: Installing Insulator On Lead Wires Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Install the rectifier holder while pushing it with the 4 screws Torque: 2.9 N.m (30 kgf.cm, 26 in..lbf)

2002 ELECTRICAL Generators & Regulators - Corolla

Fig. 48: Installing Rectifier Holder With Screws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 5. Install Voltage Regulator And Brush Holder a. Place the seal plate on the rectifier end frame.

2002 ELECTRICAL Generators & Regulators - Corolla

Fig. 49: Placing Seal Plate On Rectifier End Frame Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Place the voltage regulator and brush holder on the rectifier end frame. NOTE: Be careful of the holder installation direction.

c. Install the 5 screws. Torque: 2.0 N.m (20 kgf.cm, 18 in..lbf)

2002 ELECTRICAL Generators & Regulators - Corolla

Fig. 50: Displaying Proper Installation Of Brush Holder Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 6. Install Rear End Cover a. Place the brush holder cover on the brush holder.

2002 ELECTRICAL Generators & Regulators - Corolla

Fig. 51: Displaying Brush Holder On Brush Holder Cover Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Install the end cover and plate terminal with the bolt and 3 nuts. Torque: 4.4 N.m (45 kgf.cm, 39 in..lbf) for nut 3.9 N.m (39 kgf.cm, 35 in..lbf) for bolt

2002 ELECTRICAL Generators & Regulators - Corolla

Fig. 52: Install Rear End Cover Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Install the terminal insulator with the nut. Torque: 4.1 N.m (42 kgf.cm, 36 in..lbf) 7. Check That Rotor Rotates Smoothly

2002 ELECTRICAL Generators & Regulators - Corolla

Fig. 53: Installing Terminal Insulator With Nut Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSTALLATION 1. Install Generator a. Install the generator with the 2 bolts. Torque: 24.5 N.m (250 kgf.cm, 18 ft.lbf) for 14 mm head 54 N.m (550 kgf.cm, 40 ft.lbf) for 17 mm head b. Connect the generator connector. c. Connect the generator wire with the nut. d. Install the rubber cap. e. Install the wire clamp to the wire clip on the rectifier end frame. 2. Install Drive Belt. . See ON-VEHICLE INSPECTION .

2002 ELECTRICAL Generators & Regulators - Corolla

Fig. 54: Installing Generator With Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS Application Generator Mounting Bolt Bolt With 14-mm Bolt Head Bolt With 17-mm Bolt Head Generator Pulley Nut Ft. Lbs. (N.m) 18 (24) 40 (54) 81 (110)

2002 TOYOTA Corolla

2002 TOYOTA Corolla

BUZZERS, RELAYS & TIMERS

BUZZERS, RELAYS & TIMERS LOCATION Component A/C FAN No. 2 Relay A/C FAN No. 3 Relay A/C M/G Relay C/OPN Relay Daytime Running Light Relay (Main) DEF Relay DIMMER Relay DRL Relay EFI Or F-HTR Relay ENGINE MAIN Relay FAN No. 1 Relay FLASHER Relay Foglight Relay HEAD Relay HORN Relay HTR Relay Integration Relay Moon Roof Control Relay Power Outlet Relay P/W Relay ST Relay TAIL Relay Component Location On engine room R/B No. 5. On engine room R/B No. 5. On engine room R/B No. 5. On driver side R/B. Behind dash, above glove box. See Fig. 3 . On instrument panel J/B. On engine room R/B No. 5. On engine room R/B No. 6. On engine room J/B. On engine room J/B. On engine room J/B. On driver side R/B. On rear of driver side R/B. On engine room J/B. On engine room J/B. On engine room R/B No. 6. On rear of instrument panel J/B. See Fig. 3 . On center of windshield header. On driver side R/B. On driver side R/B. On engine room J/B. On instrument panel J/B.

CIRCUIT PROTECTION DEVICES

CIRCUIT PROTECTION DEVICES LOCATION Component Component Location Center J/B Behind center of dash. See Fig. 3 . Driver Side J/B Behind left kick panel. See Fig. 3 . Driver Side R/B Behind left kick panel. See Fig. 3 . Engine Room J/B On left side of engine compartment. See Fig. 2 . Engine Room R/B No. 5 On left front of engine compartment. See Fig. 2 . Engine Room R/B No. 6 On right front of engine compartment, on radiator support. See Fig. 2 . Fuse Holder Behind left end of dash. Fusible Link Block On top left side of engine room J/B. See Fig. 2 . Instrument Panel J/B Behind left side of dash, at lower finish panel. See Fig. 3 .

2002 TOYOTA Corolla

CONTROL UNITS
CONTROL UNITS LOCATION Component ABS Actuator & ECU A/C Amplifier Center Air Bag Sensor Assembly Cruise Control ECU Engine Control Module Shift Lock ECU Component Location On left rear of engine compartment. See Fig. 2 . Behind dash, above glove box. See Fig. 3 . Below front of center console. See Fig. 3 . Behind right kick panel. See Fig. 3 . Below center of dash. See Fig. 3 . Below center console, forward of park brake lever. See Fig. 3 .

MOTORS
MOTORS LOCATION Component A/C Condenser Fan Motor Air Inlet Servo Control Motor Blower Motor Cruise Control Actuator Front Wiper Motor Fuel Pump & Sender Moon Roof Motor & Limit Switch Radiator Fan Motor Washer Motor Component Location On right front of engine compartment. See Fig. 1 . Behind glove box. Below right side of dash, in heater-A/C housing. On right rear of engine compartment. See Fig. 1 . On right side of firewall. See Fig. 1 . In fuel tank. On center front underside of roof. On left front of engine compartment. See Fig. 1 . On left front of engine compartment, on washer fluid reservoir.

SENDING UNITS & SENSORS

SENDING UNITS & SENSORS LOCATION Component ABS Speed Sensor (Left Front) ABS Speed Sensor (Left Rear) ABS Speed Sensor (Right Front) ABS Speed Sensor (Right Rear) A/C Evaporator Temperature Sensor A/C Magnetic Clutch & Lock Sensor Air Bag Sensor (Left Front) Air Bag Sensor (Right Front) Ambient Temperature Sensor Automatic Light Control Sensor Camshaft Position Sensor Center Air Bag Sensor Assembly Component Location On inside of left front wheel assembly. See Fig. 1 . On inside of left rear wheel assembly. On inside of right front wheel assembly. See Fig. 1 . On inside of right rear wheel assembly. Behind right side of dash, on evaporator. On A/C compressor. See Fig. 1 . Behind left headlight assembly. See Fig. 1 . Behind right headlight assembly. See Fig. 1 . On middle front of engine compartment. See Fig. 1 . On top left side of dash. On left rear of engine. See Fig. 1 . Below front of center console. See Fig. 3 . On lower left front of engine, near crankshaft.

2002 TOYOTA Corolla

Crankshaft Position Sensor Engine Coolant Temperature Sensor & Water Temperature Sender Heated Oxygen Sensor (Bank 1 Sensor 1) Heated Oxygen Sensor (Bank 1 Sensor 2) Knock Sensor Mass Airflow Meter Side Air Bag Sensor (Left) Side Air Bag Sensor (Right) Throttle Position Sensor Vapor Pressure Sensor Vehicle Speed Sensor

See Fig. 1 . On rear of engine, on coolant outlet. See Fig. 1. On exhaust pipe, under vehicle. See Fig. 1 . On exhaust pipe, under center of vehicle. On left side of engine. See Fig. 1 . On left side of engine compartment, in air intake duct. On left side door sill plate area. On right side door sill plate area. On throttle body assembly. See Fig. 1 . Under rear, center of vehicle. On top of transaxle. See Fig. 1 .

SOLENOIDS & SOLENOID VALVES

SOLENOIDS & SOLENOID VALVES LOCATION Component Component Location Camshaft Timing Oil Control Valve On left front of engine. See Fig. 1 . Electronically Controlled Transmission Solenoid On transaxle. See Fig. 1 . Idle Air Control Valve On throttle body assembly. See Fig. 1 . Key Interlock Solenoid On steering column, behind ignition key cylinder. VSV (Canister Closed Valve) On left rear of engine compartment. See Fig. 1 . VSV (EVAP) On left rear of engine compartment. See Fig. 1 . VSV (Pressure Switching Valve) On center rear underside of vehicle.

SWITCHES
SWITCHES LOCATION Component A/C Triple Pressure Switch (Dual & Single) Back-Up Light Switch Brake Fluid Level Warning Switch Buckle Switch (Left) Clutch Start Switch (M/T) Cruise Control Clutch Switch (M/T) Luggage Compartment Light Switch O/D Switch Oil Pressure Switch Parking Brake Switch Park/Neutral Position Switch Power Steering Oil Pressure Switch Stoplight Switch Component Location On right front of engine compartment, near radiator support. See Fig. 1 . On transaxle. See Fig. 1 . On brake fluid reservoir. See Fig. 1 . In driver's seat belt buckle. On bracket, above clutch pedal. On bracket, above clutch pedal. On center of end panel. Below center console. On lower left side of engine. See Fig. 1 . At base of park brake lever. On left side of transaxle. See Fig. 1 . On right rear of engine compartment. See Fig. 1 . On bracket, above brake pedal.

2002 TOYOTA Corolla

Unlock Warning Switch Washer Level Warning Switch

On steering column, behind ignition key cylinder. In washer fluid reservoir.

MISCELLANEOUS
MISCELLANEOUS LOCATION Component Blower Resistor Data Link Connector (DLC) No. 1 Data Link Connector (DLC) No. 3 Diode (Buckle Switch) Diode (Daytime Running Light) (Canada) Diode (Foglight) Ignition Coil & Ignitor (4) Junction Connector No. 1 Junction Connector No. 2 Junction Connectors No. 3, 4 & 5 Junction Connectors No. 6 & 7 Junction Connectors No. 8, 9, 10, 11 & 12 Junction Connector No. 13 Junction Connector No. 14 Junction Connectors No. 15 & 16 Junction Connector No. 17 Junction Connector No. 18 Junction Connector No. 19 Junction Connector No. 20 Noise Filter (Dome) Noise Filter (Ignition) Pretensioner (Left) Pretensioner (Right) Short Pin Theft Deterrent Horn Component Location Below right side of dash, in heater-A/C housing. On left rear of engine compartment. See Fig. 1 . Below left side of dash. Behind lower left end of dash. Behind left side of dash, taped to harness. Behind upper right center of dash. On top of cylinder head, above respective cylinder. Behind left kick panel, taped to harness. In center J/B. Behind upper left side of dash, taped to harness. In center J/B. Behind lower center of dash, taped to harness. Behind upper right side of dash. Behind right kick panel, taped to harness. In left front door. In right front door. Bottom of left "C" pillar. Near left rear taillight. Behind left end of dash. On instrument panel J/B. On rear of engine. At bottom of left "B" pillar. At bottom of right "B" pillar. In instrument panel J/B. On left side of engine compartment.

CONNECTORS
CONNECTORS LOCATION Component BA1 (8 Pin) BB1 (8 Pin) BC1 (6 Pin) EA1 (Gray, 1 Pin) IA1 (3 Pin) IB1 (14 Pin) IB2 (14 Pin) Component Location Under left "B" pillar. Under right "B" pillar. Above left rear wheelwell. Under exhaust manifold. See Fig. 4 . Near left side R/B. Near left side R/B. Near left side R/B.

2002 TOYOTA Corolla

IC1 (Blue, 9 Pin) ID1 (10 Pin) ID2 (Brown, 6 Pin) IE1 (Yellow, 2 Pin) IF1 (Gray, 9 Pin) IG1 (Blue, 10 Pin) IG2 (Black, 10 Pin) IH1 (11 Pin) IH2 (3 Pin) II1 (Yellow, 2 Pin) IJ1 (12 Pin) IJ2 (Blue, 22 Pin) IK1 (16 Pin) IK2 (14 Pin) IL1 (19 Pin) IL2 (Gray, 7 Pin) IM1 (Gray, 9 Pin) IM2 (12 Pin)

Near left side J/B. Near left side J/B. Near left side J/B. Near left side J/B. At left kick panel. At left kick panel. At left kick panel. Behind left lower dash panel. Behind left lower dash panel. Behind left lower dash panel. At left dash brace. At left dash brace. At right dash brace. At right dash brace. At right dash brace. At right dash brace. At right kick panel. At right kick panel.

GROUNDS
GROUNDS LOCATION Component BI BJ BK EA EB EC ID IE IF IG IH Component Location Under left "C" pillar. At center rear of luggage compartment. Under right "C" pillar. At front side of right fender. See Fig. 4 . At front side of left fender. See Fig. 4 . At cylinder head. See Fig. 4 . At left kick panel. See Fig. 3 . At left dash brace. See Fig. 3 . At left dash brace. See Fig. 3 . At right dash brace. See Fig. 3 . At right kick panel. See Fig. 3 .

SPLICES
SPLICES LOCATION Component B1 E1 I1 I4 I6 Component Location In body harness, at center of windshield header. In engine harness, on battery. See Fig. 4 . In dash harness, at left side of dash. In dash harness, behind upper portion of left side of dash. In dash harness, behind center of dash.

2002 TOYOTA Corolla

I7 I8 I9

In dash harness, behind right side of dash. In dash harness, under left front of center console. In dash harness, under left front of center console.

COMPONENT LOCATION GRAPHICS

NOTE: Figures may show multiple component locations. Refer to appropriate table for proper figure references.

Fig. 1: Engine Compartment Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 TOYOTA Corolla

Fig. 2: Engine Compartment Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 3: Dash Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 TOYOTA Corolla

Fig. 4: Engine Compartment Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 ELECTRICAL Fuses & Circuit Breakers - Corolla

2002 ELECTRICAL Fuses & Circuit Breakers - Corolla

IDENTIFICATION
WARNING: Vehicle is equipped with air bag supplemental restraint system. Before attempting ANY repairs involving steering column, instrument panel or related components, see SERVICE PRECAUTIONS and DISABLING & ACTIVATING AIR BAG SYSTEM in appropriate TOYOTA - AIR BAG RESTRAINT SYSTEMS article. CAUTION: When battery is disconnected, vehicle computer and memory systems may lose memory data. Driveability problems may exist until computer systems have completed a relearn cycle. See appropriate COMPUTER RELEARN PROCEDURES article in GENERAL INFORMATION before disconnecting battery. ENGINE ROOM JUNCTION & RELAY BLOCKS NOTE: Numerous junction, relay and fusible link blocks are located in the engine room. See Fig. 1 . For identification of current flow, see Fig. 2 .

Component Locations

Engine room No.2 junction block is located at left side of engine room. See Fig. 1 . Engine room junction block No.2 contains relays and fuses. For identification of engine room junction block No.2 components, see Fig. 3 . For identification of engine room junction block fuse components, see Fig. 4 . The engine room No.2 junction block is the connection point for various wiring harnesses. For wiring diagrams of engine room No.2 junction block circuit components, see appropriate SYSTEM WIRING DIAGRAMS article in ELECTRICAL. Engine room No.5 relay block is located at left side of engine room. See Fig. 1 . Engine room No.5 relay block contains relays and fuses. For identification of Engine room No.5 relay block components, see Fig. 5 . For identification of engine room relay block No.5 fuse components, see Fig. 5 . The engine room relay block No.5 is the connection point for various wiring harnesses. For wiring diagrams of engine room relay block No.5 circuit components, see appropriate SYSTEM WIRING DIAGRAMS article in ELECTRICAL. Engine room No.6 relay block is located at right front of engine room. See Fig. 1 . Engine room No.6 relay block contains relays and fuses. For identification of Engine room No.6 relay block components, see Fig. 6 . For identification of engine room relay block No.6 fuse components, see Fig. 6 . The engine room relay block No.6 is the connection point for various wiring harnesses. For wiring diagrams of engine room relay block No.6 circuit components, see SYSTEM WIRING DIAGRAMS article in ELECTRICAL.

2002 ELECTRICAL Fuses & Circuit Breakers - Corolla

Fig. 1: Locating Relay & Junction Blocks Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 ELECTRICAL Fuses & Circuit Breakers - Corolla

Fig. 2: Current Flow Chart Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 ELECTRICAL Fuses & Circuit Breakers - Corolla

Fig. 3: Identifying Engine Room No. 2 Junction Block Components Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 ELECTRICAL Fuses & Circuit Breakers - Corolla

Fig. 4: Identifying Engine Room No. 2 Junction Block Fuse Components Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 ELECTRICAL Fuses & Circuit Breakers - Corolla

Fig. 5: Identifying Engine Room No. 5 Relay Block Components Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 ELECTRICAL Fuses & Circuit Breakers - Corolla

Fig. 6: Identifying Engine Room No. 6 Relay Block Components Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSTRUMENT PANEL JUNCTION & RELAY BLOCKS NOTE: Numerous junction, relay and fusible link blocks are located in the passenger room area. See Fig. 1 . For identification of current flow, see Fig. 2.

Component Locations

The instrument panel junction block is located behind left side of dash at lower finish panel. See Fig. 1 . Instrument panel junction block contains relays and fuses. See Fig. 7 . For identification of instrument panel junction block fuse components, see Fig. 8 and Fig. 9 . The instrument panel junction block assembly is the connection point for various wiring harnesses. For wiring diagrams of instrument panel junction block circuit components, see SYSTEM WIRING DIAGRAMS article in ELECTRICAL.

2002 ELECTRICAL Fuses & Circuit Breakers - Corolla

The drivers side relay block is located behind left kick panel. See Fig. 1 . drivers side relay block contains relays and fuses. See Fig. 10 . The drivers side relay block assembly is the connection point for various wiring harnesses. For wiring diagrams of drivers side relay block circuit components, see appropriate SYSTEM WIRING DIAGRAMS article in ELECTRICAL. The fog light relay is located behind left kick panel. See Fig. 1 . For wiring diagrams of fog light relay circuit components, see EXTERIOR LIGHTS in appropriate SYSTEM WIRING DIAGRAMS article in ELECTRICAL. The fuse holder is located behind left kick panel. See Fig. 1 . The fuse holder contains a 15 amp fuse for the power outlet. For wiring diagrams of fuse holder circuit components, see appropriate SYSTEM WIRING DIAGRAMS article in ELECTRICAL. The power outlet relay is located behind left kick panel. See Fig. 1 . For wiring diagrams of power outlet relay circuit components, see SYSTEM WIRING DIAGRAMS article in ELECTRICAL. The center junction block is located behind center of dash. See Fig. 1 . The center junction block is the connection point for various wiring harnesses. For wiring diagrams of center junction block circuit components, see SYSTEM WIRING DIAGRAMS article in ELECTRICAL. The daytime running light relay main is located behind left kick panel. See Fig. 1 . For daytime running light relay main wiring diagram of circuit components, see EXTERIOR LIGHTS in SYSTEM WIRING DIAGRAMS article in ELECTRICAL. The moon roof relay is located in center of windshield header. See Fig. 11 . For moon roof relay wiring diagram of circuit components, see POWER TOP/SUNROOF in SYSTEM WIRING DIAGRAMS article in ELECTRICAL.

2002 ELECTRICAL Fuses & Circuit Breakers - Corolla

Fig. 7: Identifying Instrument Panel Junction Block Components Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 ELECTRICAL Fuses & Circuit Breakers - Corolla

Fig. 8: Identifying Instrument Panel Junction Block Fuse Components (1 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 ELECTRICAL Fuses & Circuit Breakers - Corolla

Fig. 9: Identifying Instrument Panel Junction Block Fuse Components (2 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 ELECTRICAL Fuses & Circuit Breakers - Corolla

Fig. 10: Identifying Drivers Side Relay Block Components Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 ELECTRICAL Fuses & Circuit Breakers - Corolla

Fig. 11: Locating Moon Roof Relay Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 STARTING & CHARGING SYSTEMS Starters

2002 STARTING & CHARGING SYSTEMS Starters

DESCRIPTION & OPERATION

All models use Nippondenso 4-brush, solenoid-actuated, reduction gear type starters, equipped with overrunning clutches. The brush holder assembly retains 4 brushes and springs in the starter housing. Reduction gear type starters contain an integral solenoid attached to drive housing, a reduction idler gear and bearing installed into starter housing, and a clutch drive assembly. The clutch drive assembly is mounted to starter housing and is driven by the reduction idler gear from armature shaft. The brush holder assembly retains 4 brushes and 4 springs in the end cover of field frame housing. All models use a starter relay to energize starter. Manual transmission vehicles use a clutch start switch and automatic transmission vehicles use a park/neutral switch to energize starter relay. On models with theft deterrent system, theft deterrent system ECU provides ground for starter relay. Tacoma, Tundra and 4Runner models with 4WD and M/T use an optional clutch start cancel switch. When this switch is turned on, it will allow engine to be started without depressing clutch pedal when transmission is in Neutral. This allows vehicle to be driven out of difficult situations by cranking the engine with the clutch engaged.

TROUBLE SHOOTING
NOTE: NO-START 1. If a no-start condition exists and battery is known to be good, connect test light or voltmeter between starter solenoid terminal No. 50 and ground. See Fig. 9 or Fig. 10 . 2. Turn ignition switch to START position. If test light or voltmeter does not indicate voltage, check main fusible links and large ampere main fuses in engine compartment relay box. If fusible links and fuses are okay, see IGNITION SWITCH CONTINUITY TEST and/or STARTER RELAY TEST under ON-VEHICLE TESTING. See TROUBLE SHOOTING article in GENERAL INFORMATION.

ON-VEHICLE TESTING
NOTE: Before testing, ensure battery is fully charged, battery cables and terminal ends are tight and clean, and engine grounds are secure.

CLUTCH START SWITCH TEST Switch is located above clutch pedal on bracket. Disconnect wiring harness connector from switch. Connect ohmmeter between clutch start switch terminals. Depress clutch pedal. If continuity does not exist, adjust or replace clutch start switch. If continuity exists, switch is functioning properly. CLUTCH START CANCEL SWITCH TEST

2002 STARTING & CHARGING SYSTEMS Starters

Fig. 2: Clutch Start Cancel Switch Connector ID (Tundra) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. IGNITION SWITCH CONTINUITY TEST
Celica

1. Deactivate air bag system. See AIR BAG RESTRAINT SYSTEMS article. Disconnect negative battery cable. Remove driver's lower instrument panel cover. Remove upper and lower steering column covers if needed. Locate ignition switch wiring harness 6-pin connector. See Fig. 3 . 2. With ignition switch in LOCK position, there should be no continuity between any terminals. With ignition switch in ACC position, there should be continuity between terminals No. 1 and 3. With ignition switch in ON position, there should be continuity between terminals No. 1, 2 and 3, and between terminals No. 5 and 6. With ignition switch in START position, there should be continuity between terminals No. 1 and 2, and between terminals No. 4, 5 and 6. If continuity is not as specified, replace switch.
All Others

1. Deactivate air bag system. See AIR BAG RESTRAINT SYSTEMS article. Disconnect negative battery cable. Remove driver's lower instrument panel cover. Remove upper and lower steering column covers if needed. Locate ignition switch wiring harness 8-pin connector. See Fig. 4 . 2. With ignition switch in LOCK position, there should be no continuity between any terminals. With ignition switch in ACC position, there should be continuity between terminals No. 2 and 3. With ignition switch in ON position, there should be continuity between terminals No. 2, 3 and 4, and between terminals No. 6 and 7.

2002 STARTING & CHARGING SYSTEMS Starters

3. With ignition switch in START position, there should be continuity between terminals No. 1, 2 and 4, and between terminals No. 6, 7 and 8. If continuity is not as specified, replace switch.

Fig. 3: Ignition Switch 6-Pin Connector (Celica, ECHO & MR2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 4: Ignition Switch 8-Pin Connector (All Others) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. PARK/NEUTRAL SWITCH NOTE: If vehicle will not start with shift lever in Park/Neutral position, verify correct

2002 STARTING & CHARGING SYSTEMS Starters

park/neutral switch adjustment. If park/neutral switch is correctly adjusted, verify switch continuity.
Adjusting Park/Neutral Switch

Locate park/neutral switch at transmission or transaxle. Loosen park/neutral position switch bolt(s) and verify shift selector is in "N" position. Align switch shaft groove with neutral basic line on switch. Hold switch in position and tighten bolt(s) to specification. See TORQUE SPECIFICATIONS .
Park/Neutral Switch Continuity Check

Disconnect electrical connector from park/neutral switch at transmission or transaxle. Using ohmmeter, check for continuity at specified terminals with gearshift lever in proper positions. See Fig. 5 or Fig. 6 . See PARK/NEUTRAL SWITCH SPECIFICATIONS table. If continuity is not as specified, replace switch. PARK/NEUTRAL SWITCH SPECIFICATIONS Application & Gearshift Lever Position Avalon, Camry, Camry Solara, Corolla & Sienna Park Reverse Neutral Drive 2 Low Celica, Highlander, Land Cruiser, RAV4, Sequoia & 4Runner Park Reverse Neutral Drive 2 Low ECHO Park Reverse Neutral Drive 2 Low Tacoma Park Reverse Neutral Drive 2 Low Continuity Between Terminals No. 5 & 6, 2 & 7 2&8 5 & 6, 2 & 9 2 & 10 2&3 2&4 6 & 9, 3 & 1 3&2 6 & 9, 3 & 5 3&7 3&4 3&8 3 & 5, 6 & 9 3&4 1 & 3, 6 & 9 3&8 2&3 3&7 5 & 6, 4 & 7 4&8 5 & 6, 4 & 10 4&9 4&2 4&3

2002 STARTING & CHARGING SYSTEMS Starters

Tundra Park Reverse Neutral Drive 2 Low

4 & 7, 5 & 6 4&8 4 & 10, 5 & 6 4&9 4&2 4&3

Fig. 5: Identifying Park/Neutral Switch Terminals (All Others) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 STARTING & CHARGING SYSTEMS Starters

Fig. 6: Identifying Park/Neutral Switch Terminals (Celica, ECHO, Highlander, RAV4, Sequoia & 4Runner) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. STARTER RELAY TEST
Land Cruiser

1. Locate and remove starter relay. Starter relay is marked "ST". See STARTER RELAY LOCATION table. Using ohmmeter, verify continuity exists between relay terminals No. 3 and 4. See STEP 1. See Fig. 7 . Continuity should not exist between terminals No. 1 and 2. If continuity is not as specified, replace relay. 2. Check relay operation by applying battery voltage to terminals No. 3 and 4. See STEP 2. See Fig. 7 . Continuity should now exist between terminals No. 1 and 2. If relay does not test as indicated, replace relay.
All Others

1. Locate and remove starter relay. Starter relay is marked "ST". See STARTER RELAY LOCATION table. Using ohmmeter, verify continuity between relay terminals No. 1 and 2. See Fig. 8 . Continuity should not exist between terminals No. 3 and 5. If continuity is not as specified, replace relay. 2. Check relay operation by applying battery voltage through terminals No. 1 and 2. See Fig. 8 . Continuity should now exist between terminals No. 3 and 5. If relay does not test as indicated, replace relay. STARTER RELAY LOCATION

2002 STARTING & CHARGING SYSTEMS Starters

Application Avalon & Corolla Camry, Camry Solara & Sienna Celica Land Cruiser ECHO, Highlander, RAV4, Sequoia, Tundra, 4Runner MR2 Tacoma

Location In Engine Compartment Junction Block In Engine Compartment Junction Block No. 2 In Engine Compartment Junction/Relay Block No. 2 In Engine Compartment Junction Block In Engine Compartment Relay Block In Engine Fuse Link Block In Engine Compartment Relay Block No. 2

2002 STARTING & CHARGING SYSTEMS Starters

Fig. 8: Testing Starter Relay (All Others) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

BENCH TESTING
NO-LOAD TEST CAUTION: DO NOT engage starter solenoid for more than 5 seconds during testing, or damage to coil winding will result. 1. Remove starter. Connect ammeter in series between starter motor terminal No. 30 (battery terminal) and a fully charged 12-volt battery. Connect battery negative lead to starter case ground. See Fig. 9 or Fig. 10 . Connect voltmeter to battery to observe voltage draw readings. 2. Connect remote starter or jumper wire to terminals No. 30 and 50 to engage starter. Starter drive pinion gear should extend quickly and spin smoothly. Verify starter amperage draw and battery voltage draw are within specifications. See NO-LOAD TEST SPECIFICATIONS table. Replace starter if not within specification.

2002 STARTING & CHARGING SYSTEMS Starters

Fig. 10: Starter No-Load Test (Avalon & Sienna Shown; Camry, Camry Solara, Corolla, Highlander, Tacoma V6, Tundra & 4Runner V6 Are Similar) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NO-LOAD TEST SPECIFICATIONS Application (1) Max. Amps @ (Volts) Avalon, Celica, MR2 & Sienna 1.4 kW 90 (11.5) Camry, Camry Solara, Corolla, Highlander & RAV4 1.2 & 90 (11.5) 1.4 kW ECHO 0.8 kW 90 (11.5) 3000 Land Cruiser 2.0 kW 100 (11.5) 2500 Sequoia 100 (11.5) 3000 Tacoma, Tundra & 4Runner 1.2 & 1.4 kW 90 (11.5) 3000 1.8 & 2.0 kW 100 (11.5) 2500 (1) Starter type and kilowatt (kW) rating can be found on a metal label attached to side of starter. Minimum RPM 3000 3000

2002 STARTING & CHARGING SYSTEMS Starters

SOLENOID TESTS CAUTION: DO NOT engage starter solenoid for more than 5 seconds during testing, or damage to coil winding will result. 1. Pull-In Coil Test Disconnect field coil lead from terminal "C". Connect jumper wires from negative battery terminal to terminal "C" and to starter housing. When wire is connected from positive battery terminal to terminal No. 50, clutch pinion gear should extend fully. See Fig. 11 or Fig. 14 . If clutch pinion gear does not move, replace solenoid. If clutch pinion gear does move, go to next test. 2. Hold-In Coil Test With battery connected as in previous test and clutch pinion gear still extended, disconnect jumper wire from starter terminal "C". See Fig. 12 or Fig. 15 . Clutch pinion gear should remain extended. If clutch pinion gear does not remain extended, replace solenoid. If clutch pinion gear does remain extended, go to next test. 3. Drive Pinion Return Test Disconnect jumper wire from negative battery terminal to starter housing. See Fig. 13 or Fig. 16 . Pinion gear should now retract. If it does not retract, replace solenoid.

Fig. 11: Solenoid Pull-In Coil Test (Avalon, Camry & Sienna Shown; Corolla, Highlander, Sequoia,

2002 STARTING & CHARGING SYSTEMS Starters

Tacoma V6, Tundra & 4Runner V6 Are Similar) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 12: Solenoid Hold-In Coil Test (Avalon, Camry & Sienna Shown; Corolla, Highlander, Sequoia, Tacoma V6, Tundra & 4Runner V6 Are Similar) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 STARTING & CHARGING SYSTEMS Starters

Fig. 13: Solenoid Drive Pinion Return Test (Avalon, Camry, Camry Solara & Sienna Shown; Corolla, Highlander, Sequoia, Tacoma V6, Tundra & 4Runner V6 Are Similar) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 STARTING & CHARGING SYSTEMS Starters

Fig. 15: Solenoid Hold-In Coil Test (Celica Shown; ECHO, MR2, Land Cruiser, RAV4, & Tacoma 4Cyl. Are Similar) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 STARTING & CHARGING SYSTEMS Starters

Fig. 16: Solenoid Drive Pinion Return Test (Celica Shown; ECHO, MR2, Land Cruiser, RAV4, & Tacoma 4-Cyl. Are Similar) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ARMATURE COIL 1. Using ohmmeter, check for continuity between armature coil core and insulation between commutator segments. If continuity is present, replace armature. Check armature for short circuits using a growler. Replace armature as necessary. 2. Check for continuity between segments of commutator. If continuity is not present between any segment, replace armature. BRUSHES & SPRINGS 1. Check brush length. If length is less than specification, replace brushes. See STARTER SPECIFICATIONS . If brushes are okay, go to next step. 2. Check brush holders, springs, spring clip and insulation between positive and negative holders. Verify no continuity exists between positive and negative brush holders. Repair or replace components as needed. CLUTCH ASSEMBLY & GEARS

2002 STARTING & CHARGING SYSTEMS Starters

1. Inspect teeth on pinion gear, idler gear and clutch assembly for wear or damage. If damaged, replace gear or clutch assembly and inspect flywheel ring gear for wear or damage. 2. Inspect clutch pinion gear by rotating pinion gear. Depending on engine, pinion gear will rotate freely in one direction and lock when rotated in opposite direction. On Avalon, Camry, Camry Solara, Celica, RAV4 and Sienna, clutch pinion gear will lock when rotated in a clockwise direction. On all other models, pinion gear will lock in a counterclockwise direction. Replace clutch assembly as necessary. COMMUTATOR 1. If commutator surface is dirty or burnt, it can be cleaned with No. 400 grit sandpaper or on a lathe. If commutator runout (out-of-round) is more than .002" (.05 mm), turn commutator on a lathe. If commutator diameter is less than minimum, replace armature. See STARTER SPECIFICATIONS . 2. Ensure undercut depth between commutator segments are clean, free of debris, and that edges are smooth. Minimum undercut depth is .008" (.20 mm). If undercut depth is less than minimum, use a hacksaw blade to correct to a depth of .008-.024" (.20-.60 mm). FIELD FRAME (FIELD COIL) Verify continuity between lead wire and field coil brush lead. If continuity is not present, replace field coil. Verify there is no continuity between field coil end and field frame. If continuity exists, replace or repair field frame.

REMOVAL & INSTALLATION

STARTER
Removal & Installation (Avalon, Camry, Camry Solara & Sienna)

1. Disconnect negative battery cable and then positive cable. Remove battery and tray. If equipped with cruise control, remove cruise control actuator cover, cruise control actuator and actuator bracket from body mount. 2. On all models, remove starter terminal/wire cover and remove starter wires. Remove starter. To install, reverse removal procedure. Tighten starter bolts to specification. See TORQUE SPECIFICATIONS .
Removal & Installation (Celica)

1. Disconnect negative battery cable. Disconnect air intake temperature sensor connector from air cleaner assembly. If equipped, remove cruise control actuator cable from clamps. 2. On California models, remove air hose for idle-up from air cleaner hose. On all models, disconnect 4 clamps, and disconnect air cleaner cap from air cleaner case. Loosen hose clamp, and disconnect air cleaner hose from throttle body. 3. Remove air cleaner cap and air cleaner hose assembly. Remove air filter. Disconnect 2 engine wires from clamps on air cleaner case. Remove 3 bolts and air cleaner case. Remove battery. If equipped with cruise control, disconnect cruise control actuator connector. 4. Remove 3 bolts, and disconnect actuator from body bracket. On all models, disconnect starter connector. Remove nut, and disconnect starter cable. Remove 2 bolts, and disconnect oxygen sensor connector and engine wire brackets from starter. Remove starter. To install, reverse removal

2002 STARTING & CHARGING SYSTEMS Starters

procedure. Tighten starter bolts to specification. See TORQUE SPECIFICATIONS .

Removal & Installation (Corolla)

1. Disconnect negative battery cable and then positive cable. Remove battery and tray. Remove engine coolant reservoir. Remove engine splash shield from underneath right side of compartment. 2. Remove starter terminal/wire cover and remove starter wires. Remove starter bolts and starter. Note starter mounting bolt locations (bolts are different lengths). To install, reverse removal procedure. Tighten starter bolts to specification. See TORQUE SPECIFICATIONS .
Removal & Installation (Land Cruiser, Sequoia & Tundra V8)

1. Starter is located underneath intake manifold. See Fig. 17 . Disconnect negative battery cable. Remove cover from top of engine. Remove air cleaner intake hose. Disconnect accelerator cable. Remove intake manifold. See CYLINDER HEAD & MANIFOLDS in 4.7L article in ENGINES. 2. Remove starter wires and remove starter. To install, reverse removal procedure. Tighten starter bolts to specification. See TORQUE SPECIFICATIONS .

2002 STARTING & CHARGING SYSTEMS Starters

Fig. 17: Locating Intake Manifold & Starter Components (Land Cruiser, Sequoia & Tundra V8) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Removal & Installation (ECHO & MR2)

Disconnect negative battery cable. Remove front engine under cover. Disconnect starter connector. Remove

2002 STARTING & CHARGING SYSTEMS Starters

starter cable nut. Disconnect starter cable. Remove starter wires and remove starter. To install, reverse removal procedure. Tighten starter bolts to specification. See TORQUE SPECIFICATIONS .
Removal & Installation (Highlander & RAV4)

Disconnect negative battery cable. Remove engine coolant reservoir. Disconnect relay connectors, PCV hose, intake air temperature sensor connector, air cleaner intake hose, remaining hoses and lines for air cleaner removal. Remove air cleaner assembly. Disconnect starter connector. Remove starter wires and remove starter. To install, reverse removal procedure. Tighten starter bolts to specification. See TORQUE SPECIFICATIONS .
Removal & Installation (Tacoma, Tundra V6 & 4Runner)

Removal and installation is basically an unbolt and bolt-on procedure. Tighten starter bolts to specification. See TORQUE SPECIFICATIONS .

OVERHAUL
NOTE: See Fig. 18 for overhaul procedure.

2002 STARTING & CHARGING SYSTEMS Starters

Fig. 18: Exploded View Of Reduction Gear Starter (Avalon Shown; All Others Are Similar) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

STARTER SPECIFICATIONS
STARTER SPECIFICATIONS (4-CYLINDER) Application Camry & Camry Solara Brush Holder Length Standard Minimum Commutator Runout Standard Maximum Length Standard Specification

.354" (9.00 mm) .157" (4.00 mm)

.0008" (.020 mm) .0020" (.050 mm) .1299" (3.300 mm)

2002 STARTING & CHARGING SYSTEMS Starters

Maximum Snap Ring End Gap Celica & Corolla Brush Length Standard Minimum Brush Spring Load 1.2 kW Standard Minimum 1.4 kW Standard Minimum Commutator Diameter Standard Minimum Undercut Depth Standard Minimum Maximum Runout ECHO Brush Length Standard Minimum Brush Spring Load Standard Minimum Commutator Diameter Standard Minimum Undercut Depth Standard Minimum Maximum Runout Highlander Brush Length Standard Minimum Brush Spring Load Commutator Diameter Standard

.1575" (4.000 mm) .1969" (5.000 mm)

.610" (15.50 mm) .394" (10.00 mm)

3.09-4.41 Lbs. (1.4-2.0 kg) 1.98 Lbs. (.9 kg) 3.97-5.29 Lbs. (1.8-2.4 kg) 2.64 Lbs. (1.2 kg)

1.181" (30.00 mm) 1.142" (29.00 mm) .024" (.60 mm) .008" (.20 mm) .002" (.05 mm)

.551" (14.00 mm) .354" (9.00 mm) 3.09-3.97 Lbs. (1.4-1.8 kg) 1.98 Lbs. (.9 kg)

1.102" (28.00 mm) 1.063" (27.00 mm) .024" (.60 mm) .008" (.20 mm) .002" (.05 mm)

.610" (15.50 mm) .335" (8.50 mm)

(1)

1.181" (30.00 mm)

2002 STARTING & CHARGING SYSTEMS Starters

Minimum Undercut Depth Standard Minimum Maximum Runout MR2 Brush Length Standard Minimum Brush Spring Load Standard Minimum Commutator Diameter Standard Minimum Undercut Depth Standard Minimum Maximum Runout RAV4 Brush Length Standard Minimum Brush Spring Load 1.2 kW Standard Minimum 1.4 kW Standard Minimum Commutator Diameter Standard Minimum Undercut Depth Standard Minimum Maximum Runout Tacoma Brush Length 1.4 kW Standard Minimum

1.142" (29.00 mm) .024" (.60 mm) .008" (.20 mm) .002" (.05 mm)

.610" (15.50 mm) .394" (10.00 mm) 3.97-5.29 Lbs. (1.8-2.4 kg) 2.64 Lbs. (1.2 kg)

1.181" (30.00 mm) 1.142" (29.00 mm) .024" (.60 mm) .008" (.20 mm) .002" (.05 mm)

.610" (15.50 mm) .334" (8.50 mm)

3.09-4.41 Lbs. (1.4-2.0 kg) 1.98 Lbs. (.9 kg) 3.97-5.29 Lbs. (1.8-2.4 kg) 2.64 Lbs. (1.2 kg)

1.181" (30.00 mm) 1.142" (29.00 mm) .024" (.60 mm) .008" (.20 mm) .002" (.05 mm)

.610" (15.50 mm) .394" (10.00 mm)

2002 STARTING & CHARGING SYSTEMS Starters

Standard Minimum Brush Spring Load 1.4 kW Standard Minimum 2.0 kW Standard Minimum Commutator Diameter 1.4 kW Standard Minimum 2.0 kW Standard Minimum Undercut Depth 1.4 kW Standard Minimum 2.0 kW Standard Minimum Maximum Runout (1) Information not available from manufacturer. STARTER SPECIFICATIONS (V6) Application Avalon Brush Length Standard Minimum Brush Spring Load Standard Minimum Commutator Diameter Standard Minimum Undercut Depth Standard Minimum

.591" (15.00 mm) .354" (9.00 mm)

3.97-5.29 Lbs. (1.8-2.4 kg) 2.64 Lbs. (1.2 kg) 4.85-6.17 Lbs. (2.2-2.8 kg) 2.86 Lbs. (1.3 kg)

1.181" (30.00 mm) 1.142" (29.00 mm) 1.378" (35.00 mm) 1.338" (34.00 mm)

.024" (.60 mm) .008" (.20 mm) .028" (.70 mm) .008" (.20 mm) .002" (.05 mm)

Specification

.610" (15.50 mm) .394" (10.00 mm) 3.97-5.29 Lbs. (1.8-2.4 kg) 2.6 Lbs. (1.2 kg)

1.181" (30.00 mm) 1.142" (29.00 mm) .024" (.60 mm) .008" (.20 mm)

2002 STARTING & CHARGING SYSTEMS Starters

Maximum Runout Camry Brush Holder Length Standard Minimum Commutator Runout Standard Maximum Length Standard Maximum Snap Ring End Gap Camry Solara Brush Length Standard Minimum Brush Spring Load Standard Minimum Commutator Diameter Standard Minimum Undercut Depth Standard Minimum Maximum Runout Highlander Brush Length Standard Minimum Brush Spring Load Commutator Diameter Standard Minimum Undercut Depth Standard Minimum Maximum Runout Sienna Brush Length Standard

.002" (.05 mm)

.354" (9.00 mm) .157" (4.00 mm)

.0008" (.020 mm) .0020" (.050 mm) .1299" (3.300 mm) .1575" (4.000 mm) .1969" (5.000 mm)

.610" (15.50 mm) .394" (10.00 mm) 3.97-5.29 Lbs. (1.8-2.4 kg) 2.64 Lbs. (1.2 kg)

1.181" (30.00 mm) 1.142" (29.00 mm) .024" (.60 mm) .008" (.20 mm) .002" (.05 mm)

.610" (15.50 mm) .335" (8.50 mm)

(1)

1.181" (30.00 mm) 1.142" (29.00 mm) .024" (.60 mm) .008" (.20 mm) .002" (.05 mm)

.610" (15.50 mm)

2002 STARTING & CHARGING SYSTEMS Starters

Minimum Brush Spring Load Standard Minimum Commutator Diameter Standard Minimum Undercut Depth Standard Minimum Maximum Runout Tacoma & 4Runner Brush Length 1.4 kW Standard Minimum 1.8 kW Standard Minimum Brush Spring Load 1.4 kW Standard Minimum 1.8 kW Standard Minimum Commutator Diameter 1.4 kW Standard Minimum 1.8 kW Standard Minimum Undercut Depth 1.4 kW Standard Minimum 1.8 kW Standard Minimum Maximum Runout Tundra

.394" (10.00 mm) 3.97-5.29 Lbs. (1.8-2.4 kg) 2.64 Lbs. (1.2 kg)

1.181" (30.00 mm) 1.142" (29.00 mm) .024" (.60 mm) .008" (.20 mm) .002" (.05 mm)

.610" (15.50 mm) .394" (10.00 mm) .591" (15.00 mm) .354" (9.00 mm)

3.97-5.29 Lbs. (1.8-2.4 kg) 2.64 Lbs. (1.2 kg) 4.85-6.17 Lbs. (2.2-2.8 kg) 2.86 Lbs. (1.3 kg)

1.181" (30.00 mm) 1.142" (29.00 mm) 1.378" (35.00 mm) 1.338" (34.00 mm)

.024" (.60 mm) .008" (.20 mm) .028" (.70 mm) .008" (.20 mm) .002" (.05 mm)

2002 STARTING & CHARGING SYSTEMS Starters

1.2 kW & 1.4 kW Standard Minimum 1.8 kW Standard Minimum Brush Spring Load 1.2 kW Standard Minimum 1.4 kW Standard Minimum 1.8 kW Standard Minimum Commutator Diameter 1.2 kW & 1.4 kW Standard Minimum 1.8 kW Standard Minimum Undercut Depth 1.2 kW & 1.4 kW Standard Minimum 1.8 kW Standard Minimum (1) Information not available from manufacturer. STARTER SPECIFICATIONS (V8) Application Land Cruiser Brush Length Standard Minimum Brush Spring Load Standard Minimum Commutator

.610" (15.50 mm) .394" (10.00 mm) .591" (15.00 mm) .354" (9.00 mm)

3.09-4.40 Lbs. (1.4-2.0 kg) 2.20 Lbs. (1.0 kg) 3.97-5.29 Lbs. (1.8-2.4 kg) 2.64 Lbs. (1.2 kg) 4.85-6.17 Lbs. (2.2-2.8 kg) 2.86 Lbs. (1.3 kg)

1.181" (30.00 mm) 1.142" (29.00 mm) 1.378" (35.00 mm) 1.338" (34.00 mm)

.024" (.60 mm) .008" (.20 mm) .028" (.70 mm) .008" (.20 mm)

Specification

.591" (15.00 mm) .354" (9.00 mm) 4.85-6.17 Lbs. (2.2-2.8 kg) 2.86 Lbs. (1.3 kg)

2002 STARTING & CHARGING SYSTEMS Starters

Diameter Standard Minimum Undercut Depth Standard Minimum Maximum Runout Sequoia Brush Length 1.4 kW Standard Minimum 2.0 kW Standard Minimum Brush Spring Load 1.4 kW Standard Minimum 2.0 kW Standard Minimum Commutator Diameter Standard Minimum Undercut Depth Standard Minimum Maximum Runout Tundra Brush Length 1.4 kW Standard Minimum 2.0 kW Standard Minimum Brush Spring Load 1.4 kW Standard Minimum 2.0 kW Standard

1.378" (35.00 mm) 1.338" (34.00 mm) .028" (.70 mm) .008" (.20 mm) .002" (.05 mm)

.610" (15.50 mm) .334" (8.50 mm) .591" (15.00 mm) .354" (9.00 mm)

3.97-4.63 Lbs. (1.8-2.1 kg) 2.64 Lbs. (1.2 kg) 4.85-6.17 Lbs. (2.2-2.8 kg) 2.86 Lbs. (1.3 kg)

1.378" (35.00 mm) 1.338" (34.00 mm) .028" (.70 mm) .008" (.20 mm) .002" (.05 mm)

.610" (15.50 mm) .394" (10.00 mm) .591" (15.00 mm) .354" (9.00 mm)

3.97-5.29 Lbs. (1.8-2.4 kg) 2.64 Lbs. (1.2 kg) 4.85-6.17 Lbs. (2.2-2.8 kg)

2002 STARTING & CHARGING SYSTEMS Starters

2.86 Lbs. (1.3 kg) Commutator Diameter 1.4 kW Standard Minimum 2.0 kW Standard Minimum Undercut Depth 1.4 kW Standard Minimum 2.0 kW Standard Minimum Maximum Runout

1.181" (30.00 mm) 1.142" (29.00 mm) 1.378" (35.00 mm) 1.338" (34.00 mm)

.024" (.60 mm) .008" (.20 mm) .028" (.70 mm) .008" (.20 mm) .002" (.05 mm)

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS Application Starter Mounting Bolt Avalon Camry 2.4L 4-Cyl. 3.0L V6 Camry Solara & Celica Corolla & ECHO Highlander 2.4L 4-Cyl. 3.0L V6 Land Cruiser MR2 & RAV4 Sequoia Sienna Tacoma, Tundra & 4Runner Starter Through Bolt Avalon Camry Camry Solara 2.4L 4-Cyl. 3.0L V6 Ft. Lbs. (N.m) 29 (39) 29 (39) 31 (42) 27 (37) 28 (38) 29 (39) 31 (42) 29 (39) 28 (38) 29 (39) 27 (37) 29 (39) INCH Lbs. (N.m) 52 (5.9) 53 (6.0) 53 (6.0) 52 (5.9)

2002 STARTING & CHARGING SYSTEMS Starters

Celica, Corolla, ECHO, Highlander, MR2, RAV4 & Sienna Land Cruiser & Sequoia Tacoma 1.4 kW 1.8 kW & 2.0 kW Tundra 1.2 kW & 1.4 kW 1.8 kW & 2.0 kW 4Runner 1.4 kW 1.8 kW

52 (5.9) 82 (9.3) 52 (5.9) 82 (9.3) 52 (5.9) 82 (9.3) 52 (5.9) 82 (9.3)

WIRING DIAGRAMS

2002 STARTING & CHARGING SYSTEMS Starters

Fig. 24: Starting System Wiring Diagram (Corolla)

2002 ENGINE PERFORMANCE On-Vehicle Adjustments - 4-Cylinder

2002 ENGINE PERFORMANCE On-Vehicle Adjustments - 4-Cylinder

SERVICE PRECAUTIONS
PRIUS WARNING: When performing any inspection or service procedure on this vehicle, ensure following service precautions are followed to prevent personal injury or death due to the extremely high voltage. The following service precautions must be followed:

Ensure ignition is off and ignition key is removed from ignition before performing any inspection or service procedure in engine compartment, as engine may automatically start and shut off when ignition is on and READY light is illuminated. READY light is displayed just above the shift lever position indicator on instrument cluster at center of instrument panel. Read all service and warning labels in engine compartment before performing any procedures in engine compartment. All high-voltage wiring harness connectors contain Orange connectors. DO NOT touch any wiring harness that contains Orange connectors. High-voltage battery and other high-voltage components may be identified by HIGH VOLTAGE caution labels on them. DO NOT touch these components. If necessary to inspect or service high-voltage system, ensure ignition is off. Remove service plug and wait at least 5 minutes to ensure high voltage is fully discharged before touching any high-voltage wiring harness, connectors or components. Service plug is located on service plug assembly at driver's side front corner of trunk compartment, near high-voltage battery. See Fig. 1 . Ensure service plug is stored in a location in which no one may install service plug while technician is working on the vehicle. If necessary to touch any high-voltage wiring harness, connectors or components, ensure service plug is removed and battery voltage or less exists at electrical connector. Use Toyota insulated gloves when touching any high-voltage wiring harness, connectors or components. Ensure insulated gloves are dry and in good condition and that no holes exist by applying air pressure to insulated glove before touching any high-voltage wiring harness, connectors or components. DO NOT wear any metal objects while working on vehicle which may accidently drop and cause a short circuit. If any high-voltage wiring harness connector is disconnected, ensure terminal on wiring harness connector is wrapped with tape to prevent wiring harness connector from contacting any surface. If servicing high-voltage system, place sign on roof of vehicle to indicate to other technicians that high-voltage system is being serviced.

2002 ENGINE PERFORMANCE On-Vehicle Adjustments - 4-Cylinder

Camry

NOTE:

Following procedure should be performed if battery is disconnected and reconnected, or battery is discharged and recharged to provide proper automatic operation and jam protection operation of power sun roof.

1. Ensure ignition is on. Depress and hold TILT UP side of power sun roof switch until power sun roof tilts all the way upward and then tilts downward a little. Power sun roof switch is located on headliner, just in front of power sun roof. 2. Check proper operation of open/closing and tilt up/down function for power sun roof using power sun roof switch. Power sun roof should operate anytime ignition is on, or for 43 seconds after ignition is off provided both front doors are closed. Power sun roof will stop operating if any front door is opened. Depressing SLIDE OPEN side of power sun roof switch for one second should open power sun roof. Depressing TILT UP side of power sun roof switch for one second should close power sun roof. To tilt power sun roof upward, depress and hold TILT UP side of power sun roof switch for one second. To tilt power sun roof downward, depress and hold SLIDE OPEN side of power sun roof switch for one second.
Celica

NOTE:

Following procedure should be performed if battery is disconnected and reconnected, or battery is discharged and recharged to provide proper automatic operation and jam protection operation of power sun roof.

Close power sun roof using power sun roof switch and continue to depress power sun roof switch briefly after power sun roof is fully closed. Power sun roof switch is located on headliner, just in front of power sun roof.

ENGINE MECHANICAL
NOTE: Before performing on-vehicle adjustments, check for any related Technical Service Bulletins (TSBs).

Before performing any on-vehicle adjustments to fuel or ignition systems, ensure engine mechanical condition is okay. NOTE: On Camry and Celica, it may be possible that power sun roof may not operate properly if battery is disconnected. If power sun roof does not operate properly, perform appropriate power sun roof reinitialization procedure. See appropriate POWER SUN ROOF REINITIALIZATION PROCEDURE under PROGRAMMING.

VALVE CLEARANCE NOTE: Check and adjust valve clearance with engine cold.

Camry & Highlander

1. Raise and support vehicle. Remove passenger's side front wheel. Remove necessary fender aprons for

2002 ENGINE PERFORMANCE On-Vehicle Adjustments - 4-Cylinder

access to crankshaft pulley. Remove No. 2 cylinder head cover located on top of engine, above ignition coils and valve cover. Disconnect electrical connectors at ignition coils mounted on top of valve cover. Remove bolts and ignition coils from valve cover. Disconnect hoses and engine wiring harness clamp from valve cover. 2. Remove valve cover bolts/nuts, seal washers, valve cover and gasket. Rotate crankshaft clockwise (viewed from timing chain end of engine) until crankshaft pulley timing mark (groove) aligns with "0" mark on timing chain cover and cylinder No. 1 is at TDC on compression stroke. Cylinder No. 1 is front cylinder at timing chain end of engine. 3. Ensure timing marks on camshaft sprockets are aligned with timing marks on camshaft bearing caps. See Fig. 2 . If timing marks are not as specified, rotate crankshaft clockwise one full revolution (360 degrees) and realign crankshaft pulley timing mark (groove) with "0" mark on timing chain cover and then recheck timing mark alignment.

Fig. 2: Checking Timing Mark Alignment (Camry & Highlander) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 4. With cylinder No. 1 at TDC on compression stroke, use feeler gauge to measure valve clearance between valve lifter and camshaft on specified valves. Perform STEP 1 in illustration. See Fig. 3 . Record valve clearance. 5. To check remaining valves, rotate crankshaft clockwise one full revolution (360 degrees) and realign crankshaft pulley timing mark (groove) with "0" mark on timing chain cover. Using feeler gauge, measure valve clearance between valve lifter and camshaft on specified valves. Perform STEP 2 in illustration. See Fig. 3 . Record valve clearance.

2002 ENGINE PERFORMANCE On-Vehicle Adjustments - 4-Cylinder

Fig. 3: Identifying Cylinder Numbers & Checking Valve Clearance (Camry, Camry Solara, Highlander & RAV4) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 6. Ensure valve clearance is within specification. See VALVE CLEARANCE SPECIFICATIONS

2002 ENGINE PERFORMANCE On-Vehicle Adjustments - 4-Cylinder

(CAMRY & HIGHLANDER) table. VALVE CLEARANCE SPECIFICATIONS (CAMRY & HIGHLANDER)
(1) In. (mm) Application Intake .007-.011 (.19-.29) Exhaust .012-.016 (.30-.40) (1) Adjust valve clearance with engine cold. Verify valve clearance listed with valve clearance listed on underhood label (if available). If valve clearance on underhood label differs from valve clearance listed, use specification on underhood label.

7. If valve clearance requires adjustment, camshafts must be removed for access to valve lifters. Different thickness valve lifters are used. Manufacturer recommends placing reference mark on timing chain and camshaft sprockets, removing timing chain tensioner and then removing camshaft sprockets and camshafts for access to valve lifter while supporting timing chain. To remove camshafts, see appropriate article in ENGINES. 8. Remove valve lifter from cylinder head. Using micrometer, measure thickness of valve lifter. See Fig. 4 . Using thickness of used valve lifter and measured clearance, determine correct thickness of valve lifter to be used by using following equation for proper valve. For intake valves, "A" (new valve lifter thickness) = "B" (used valve lifter thickness) + "C" (measured clearance) minus .0094" (.240 mm). For exhaust valves, "A" (new valve lifter thickness) = "B" (used valve lifter thickness) + "C" (measured clearance) minus .0138" (.350 mm). Valve lifters are available in 35 sizes ranging from .1992" (5.060 mm) to .2260" (5.740 mm) in increments of .0008" (.020 mm).

Fig. 4: Measuring Valve Lifter Thickness (Camry, Camry Solara, Celica 1.8L 1ZZ-FE, Corolla, ECHO, Highlander, MR2, Prius & RAV4) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 9. Install replacement valve lifter, camshafts and timing chain. Recheck valve clearance. To ensure proper valve timing after reinstalling camshafts and timing chain, check that timing marks on

2002 ENGINE PERFORMANCE On-Vehicle Adjustments - 4-Cylinder

camshaft sprockets are aligned with timing marks on camshaft bearing caps when crankshaft pulley timing mark (groove) is aligned with "0" mark on timing chain cover and cylinder No. 1 is at TDC on compression stroke. See Fig. 2 . 10. Before installing valve cover and gasket, apply sealant at specified areas on cylinder head. See Fig. 5 . Install gasket, valve cover, seal washers, bolts and nuts. On Camry, tighten valve cover bolts/nuts to specification. See TORQUE SPECIFICATIONS . On Highlander, tighten valve cover bolts/nuts to specification. See Fig. 6 . To install remaining components, reverse removal procedure. Tighten ignition coil bolts and wheel lug nut to specification. See TORQUE SPECIFICATIONS .

Fig. 5: Locating Valve Cover Sealant Application Areas (Camry & Highlander) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 ENGINE PERFORMANCE On-Vehicle Adjustments - 4-Cylinder

Fig. 6: Installing & Tightening Valve Cover Bolt/Nuts (Highlander) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Camry Solara & RAV4

1. Remove passenger's side lower engine cover for access to crankshaft pulley. On RAV4, remove air cleaner assembly. On all models, disconnect electrical connectors at ignition coils mounted on top of valve cover. Remove bolts and ignition coils from valve cover. Disconnect PCV hoses from valve cover. 2. Remove valve cover bolts/nuts, valve cover and gasket. Rotate crankshaft clockwise (viewed from timing chain end of engine) until crankshaft pulley timing mark (groove) aligns with "0" mark on timing chain cover and cylinder No. 1 is at TDC on compression stroke. Cylinder No. 1 is front cylinder at timing chain end of engine. 3. Ensure timing marks on camshaft sprockets are aligned with timing marks on camshaft bearing caps. See Fig. 7 . If timing marks are not as specified, rotate crankshaft clockwise one full revolution (360 degrees) and realign crankshaft pulley timing mark (groove) with "0" mark on timing chain cover and then recheck timing mark alignment.

2002 ENGINE PERFORMANCE On-Vehicle Adjustments - 4-Cylinder

Fig. 7: Checking Timing Mark Alignment (Camry Solara & RAV4) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 4. With cylinder No. 1 at TDC on compression stroke, use feeler gauge to measure valve clearance between valve lifter and camshaft on specified valves. Perform STEP 1 in illustration. See Fig. 3 . Record valve clearance. 5. To check remaining valves, rotate crankshaft clockwise one full revolution (360 degrees) and realign crankshaft pulley timing mark (groove) with "0" mark on timing chain cover. Using feeler gauge, measure valve clearance on specified valves. Perform STEP 2 in illustration. See Fig. 3 . Record valve clearance. 6. Ensure valve clearance is within specification. See VALVE CLEARANCE SPECIFICATIONS (CAMRY SOLARA & RAV4) table. VALVE CLEARANCE SPECIFICATIONS (CAMRY SOLARA & RAV4)
(1) In. (mm) Application Intake .007-.011 (.19-.29) Exhaust .012-.016 (.30-.40) (1) Adjust valve clearance with engine cold. Verify valve clearance listed with valve clearance listed on underhood label (if available). If valve clearance on underhood label differs from valve clearance listed, use specification on underhood label.

7. If valve clearance requires adjustment, camshafts must be removed for access to valve lifters.

2002 ENGINE PERFORMANCE On-Vehicle Adjustments - 4-Cylinder

Different thickness valve lifters are used. Manufacturer recommends placing reference mark on timing chain and camshaft sprockets, removing timing chain tensioner and then removing camshaft sprockets and camshafts for access to valve lifter while supporting timing chain. To remove camshafts, see appropriate article in ENGINES. 8. Remove valve lifter from cylinder head. Using micrometer, measure thickness of valve lifter. See Fig. 4 . Using thickness of used valve lifter and measured clearance, determine correct thickness of valve lifter to be used for proper valve by using the follow equation, or using valve lifter selection charts. For intake valves, "N" (new valve lifter thickness) = "T" (used valve lifter thickness) + "A" (measured clearance) minus .0094" (.240 mm). For exhaust valves, "N" (new valve lifter thickness) = "T" (used valve lifter thickness) + "A" (measured clearance) minus .0138" (.350 mm). Valve lifters are available in 35 sizes ranging from .1992" (5.060 mm) to .2260" (5.740 mm) in increments of .0008" (.020 mm). For valve lifter selection charts, see Fig. 9 and Fig. 10 . 9. Install replacement valve lifter, camshafts and timing chain. Recheck valve clearance. To ensure proper valve timing after reinstalling camshafts and timing chain, check that timing marks on camshaft sprockets are aligned with timing marks on camshaft bearing caps when crankshaft pulley timing mark (groove) is aligned with "0" mark on timing chain cover and cylinder No. 1 is at TDC on compression stroke. See Fig. 7 . 10. Before installing valve cover and gasket, apply sealant at specified areas on cylinder head. See Fig. 8 . Install gasket, valve cover, bolts and nuts. Tighten valve cover bolts/nuts to specification. See TORQUE SPECIFICATIONS . To install remaining components, reverse removal procedure. Tighten ignition coil bolts to specification. See TORQUE SPECIFICATIONS .

Fig. 8: Locating Valve Cover Sealant Application Areas (Camry Solara & RAV4) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 ENGINE PERFORMANCE On-Vehicle Adjustments - 4-Cylinder

Fig. 9: Intake Valve Lifter Selection Chart (Camry Solara & RAV4) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 ENGINE PERFORMANCE On-Vehicle Adjustments - 4-Cylinder

Fig. 10: Exhaust Valve Lifter Selection Chart (Camry Solara & RAV4) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Celica 1.8L 1ZZ-FE, Corolla & MR2

1. Remove No. 2 cylinder head cover located on top of engine, above ignition coils and valve cover. Disconnect electrical connectors at ignition coils mounted on top of valve cover. Remove bolts and ignition coils from valve cover. Disconnect PCV hoses from valve cover. 2. Remove valve cover bolts/nuts, seal washers, valve cover and gasket. Rotate crankshaft clockwise (viewed from timing chain end of engine) until crankshaft pulley timing mark (groove) aligns with "0" mark on timing chain cover and cylinder No. 1 is at TDC on compression stroke. Cylinder No. 1 is front cylinder at timing chain end of engine. 3. Ensure reference marks on camshaft sprockets are aligned and positioned in a straight line at top surface on timing chain cover. See Fig. 11 -Fig. 13 . If reference marks are not as specified, rotate crankshaft clockwise one full revolution (360 degrees) and realign crankshaft pulley timing mark (groove) with "0" mark on timing chain cover and then recheck reference mark alignment.

2002 ENGINE PERFORMANCE On-Vehicle Adjustments - 4-Cylinder

Fig. 11: Checking Reference Mark Alignment (Celica 1.8L 1ZZ-FE & 1.8L 2ZZ-GE) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 ENGINE PERFORMANCE On-Vehicle Adjustments - 4-Cylinder

Fig. 12: Checking Reference Mark Alignment (Corolla) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 ENGINE PERFORMANCE On-Vehicle Adjustments - 4-Cylinder

Fig. 13: Checking Reference Mark Alignment (MR2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 4. With cylinder No. 1 at TDC on compression stroke, use feeler gauge to measure valve clearance between valve lifter and camshaft on specified valves. Perform STEP 1 in illustration. See Fig. 14 . Record valve clearance. 5. To check remaining valves, rotate crankshaft clockwise one full revolution (360 degrees) and realign crankshaft pulley timing mark (groove) with "0" mark on timing chain cover. Using feeler gauge, measure valve clearance on specified valves. Perform STEP 2 in illustration. See Fig. 14 . Record valve clearance.

2002 ENGINE PERFORMANCE On-Vehicle Adjustments - 4-Cylinder

Fig. 14: Identifying Cylinder Numbers & Checking Valve Clearance (Celica 1.8L 1ZZ-FE, Corolla & MR2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 6. Ensure valve clearance is within specification. See VALVE CLEARANCE SPECIFICATIONS (CELICA 1.8L 1ZZ-FE, COROLLA & MR2) table. VALVE CLEARANCE SPECIFICATIONS (CELICA 1.8L 1ZZ-FE, COROLLA & MR2)
(1) In. (mm) Application Intake .006-.010 (.15-.25) Exhaust .010-.014 (.25-.35) (1) Adjust valve clearance with engine cold. Verify valve clearance listed with valve clearance listed on underhood label (if available). If valve clearance on underhood label differs from valve clearance listed, use specification on underhood label.

2002 ENGINE PERFORMANCE On-Vehicle Adjustments - 4-Cylinder

7. If valve clearance requires adjustment, camshafts must be removed for access to valve lifters. Different thickness valve lifters are used. Manufacturer recommends placing reference mark on timing chain and camshaft sprockets, removing timing chain tensioner and then removing camshaft sprockets and camshafts for access to valve lifter while supporting timing chain. To remove camshafts, see appropriate article in ENGINES. 8. Remove valve lifter from cylinder head. Using micrometer, measure thickness of valve lifter. See Fig. 4 . Using thickness of used valve lifter and measured clearance, determine correct thickness of valve lifter to be used for proper valve by using the follow equation, or using valve lifter selection charts. For intake valves, "N" (new valve lifter thickness) = "T" (used valve lifter thickness) + "A" (measured clearance) minus .0080" (.200 mm). For exhaust valves, "N" (new valve lifter thickness) = "T" (used valve lifter thickness) + "A" (measured clearance) minus .0120" (.300 mm). Valve lifters are available in 35 sizes ranging from .1992" (5.060 mm) to .2260" (5.740 mm) in increments of .0008" (.020 mm). For valve lifter selection charts, see Fig. 17 and Fig. 18 . 9. Install replacement valve lifter, camshafts and timing chain. Recheck valve clearance. To ensure proper valve timing after reinstalling camshafts and timing chain, check that reference marks on camshaft sprockets are aligned and positioned in a straight line at top surface on timing chain cover when crankshaft pulley timing mark (groove) is aligned with "0" mark on timing chain cover and cylinder No. 1 is at TDC on compression stroke. See Fig. 11 -Fig. 13 . 10. Before installing valve cover and gasket, apply sealant at specified areas on cylinder head. See Fig. 15 . Install gasket, valve cover, seal washers, bolts and nuts. On Celica, tighten valve cover bolts/nuts to specification. See TORQUE SPECIFICATIONS . On Corolla and MR2, tighten valve cover bolts/nuts to specification in sequence. See Fig. 16 . See TORQUE SPECIFICATIONS . On all models, to install remaining components, reverse removal procedure. Tighten ignition coil bolts to specification. See TORQUE SPECIFICATIONS .

2002 ENGINE PERFORMANCE On-Vehicle Adjustments - 4-Cylinder

Fig. 15: Locating Valve Cover Sealant Application Areas (Celica, Corolla, ECHO, MR2 & Prius) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 16: Typical Valve Cover Bolt/Nut Tightening Sequence (Corolla & MR2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 ENGINE PERFORMANCE On-Vehicle Adjustments - 4-Cylinder

Fig. 17: Intake Valve Lifter Selection Chart (Celica 1.8L 1ZZ-FE, Corolla, ECHO, MR2 & Prius) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 ENGINE PERFORMANCE On-Vehicle Adjustments - 4-Cylinder

Fig. 18: Exhaust Valve Lifter Selection Chart (Celica 1.8L 1ZZ-FE, Corolla, ECHO, MR2 & Prius) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Celica 1.8L 2ZZ-GE

1. Remove No. 2 cylinder head cover located on top of engine, above ignition coils and valve cover. Disconnect electrical connectors at ignition coils mounted on top of valve cover. Remove bolts and ignition coils from valve cover. Disconnect PCV hoses from valve cover. 2. Remove bolts/nuts and disconnect ventilation hose with and ventilation pipe and gasket from front corner of valve cover. Remove valve cover bolts, valve cover and gasket. 3. Rotate crankshaft clockwise (viewed from timing chain end of engine) until crankshaft pulley timing mark (groove) aligns with "0" mark on timing chain cover and cylinder No. 1 is at TDC on compression stroke. Cylinder No. 1 is front cylinder at timing chain end of engine. 4. Ensure reference marks on camshaft sprockets are aligned and positioned in a straight line at top surface on timing chain cover. See Fig. 11 . If reference marks are not as specified, rotate crankshaft clockwise one full revolution (360 degrees) and realign crankshaft pulley timing mark (groove) with "0" mark on timing chain cover and then recheck reference mark alignment. 5. With cylinder No. 1 at TDC on compression stroke, use feeler gauge to measure valve clearance between rocker arm and camshaft lobe on both valves on specified cylinders. Perform STEP 1 in illustration. See Fig. 19 . Record valve clearance. 6. To check remaining valves, rotate crankshaft clockwise one full revolution (360 degrees) and realign crankshaft pulley timing mark (groove) with "0" mark on timing chain cover. Using feeler gauge, measure valve clearance between rocker arm and camshaft lobe on both valves on specified cylinders.

2002 ENGINE PERFORMANCE On-Vehicle Adjustments - 4-Cylinder

Perform STEP 2 in illustration. See Fig. 19 . Record valve clearance.

2002 ENGINE PERFORMANCE On-Vehicle Adjustments - 4-Cylinder

Fig. 19: Identifying Cylinder Numbers & Checking Valve Clearance (Celica 1.8L 2ZZ-GE) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 7. Ensure valve clearance is within specification. See VALVE CLEARANCE SPECIFICATIONS (CELICA 1.8L 2ZZ-GE) table. VALVE CLEARANCE SPECIFICATIONS (CELICA 1.8L 2ZZ-GE)
(1) In. (mm) Application Intake .003-.007 (.08-.19) Exhaust .008-.013 (.22-.33) (1) Adjust valve clearance with engine cold. Verify valve clearance listed with valve clearance listed on underhood label (if available). If valve clearance on underhood label differs from valve clearance listed, use specification on underhood label.

8. If valve clearance requires adjustment, remove spark plug on cylinder in which valve clearance adjustment is required so compression is released. Rotate crankshaft so rocker arm for valve to be adjusted is pushed fully downward by the camshaft lobe. Perform STEP 1 in illustration. See Fig. 20 . 9. Install Valve Spring Compressor (SST 09248-77010) on spark plug tube. Perform STEP 2 in illustration. See Fig. 20 . Set screw must be loosened so valve spring compressor fully seats on spark plug tube. Operate lever so plate fully seats against valve spring retainer and tighten set screw. Perform STEP 3 in illustration. See Fig. 20 . Ensure no clearance exists between plate and valve spring retainer, as any clearance may cause the valve keeper to be released. 10. Carefully rotate crankshaft so camshaft lobe is positioned upward, away from rocker arm. Ensure camshaft lobe does not contact valve spring compressor when rotating camshaft. Lift rocker arm assembly upward. Using Adjusting Shim Remover/Installer (SST 09248-07020), remove adjusting shim from top of valve stem. Perform STEP 4 in illustration. See Fig. 20 .

2002 ENGINE PERFORMANCE On-Vehicle Adjustments - 4-Cylinder

Fig. 20: Removing & Installing Adjusting Shim (Celica 1.8L 2ZZ-GE) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 11. Using dial indicator, measure thickness of removed adjusting shim. See Fig. 21 . Using thickness of used adjusting shim and measured clearance, determine correct thickness of adjusting shim to be used for proper valve by using the follow equation, or using adjusting shim selection charts. For intake valves, "N" (new adjusting shim thickness) = "T" (used adjusting shim thickness) + "A" (measured clearance) minus .0051" (.130 mm). For exhaust valves, "N" (new adjusting shim thickness) =

2002 ENGINE PERFORMANCE On-Vehicle Adjustments - 4-Cylinder

"T" (used adjusting shim thickness) + "A" (measured clearance) minus .0106" (.270 mm). Adjusting shims are available in 41 sizes ranging from .0787" (2.000 mm) to .1102" (2.800 mm) in increments of .0008" (.020 mm). For adjusting shim selection charts, see Fig. 22 and Fig. 23 . 12. Lift rocker arm assembly upward. Using adjusting shim remover/installer, install replacement adjusting shim. Rotate crankshaft so rocker arm is pushed fully downward by the camshaft lobe. Ensure camshaft lobe does not contact valve spring compressor when rotating camshaft. Operate lever to remove plate from valve spring retainer. Loosen set screw and remove valve spring compressor. Recheck valve clearance. 13. Install spark plug and tighten to 13 ft. lbs. (18 N.m). Before installing valve cover and gasket, apply sealant at specified areas on cylinder head. See Fig. 15 . Install gasket, valve cover and valve cover bolts. Tighten valve cover bolts to specification. See TORQUE SPECIFICATIONS . 14. Using NEW gasket, install ventilation pipe. Tighten ventilation pipe bolts/nuts to specification. See TORQUE SPECIFICATIONS . Install ignition coils. Tighten ignition coil bolts to specification. See TORQUE SPECIFICATIONS .

Fig. 21: Measuring Adjusting Shim Thickness (Celica 1.8L 2ZZ-GE) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 ENGINE PERFORMANCE On-Vehicle Adjustments - 4-Cylinder

Fig. 22: Intake Valve Adjusting Shim Selection Chart (Celica 1.8L 2ZZ-GE) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 ENGINE PERFORMANCE On-Vehicle Adjustments - 4-Cylinder

Fig. 23: Exhaust Valve Adjusting Shim Selection Chart (Celica 1.8L 2ZZ-GE) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 ENGINE PERFORMANCE On-Vehicle Adjustments - 4-Cylinder

ECHO & Prius

WARNING: On Prius, read service precautions before proceeding with service procedure. See SERVICE PRECAUTIONS . 1. On ECHO, remove No. 2 cylinder head cover located on top of engine, above ignition coils and valve cover. On Prius, remove air cleaner assembly located above the valve cover. On all models, disconnect electrical connectors at ignition coils mounted on top of valve cover. Remove bolts and ignition coils from valve cover. Disconnect PCV hoses from valve cover. 2. Remove valve cover bolts/nuts, seal washers, valve cover and gasket. Rotate crankshaft clockwise (viewed from timing chain end of engine) until crankshaft pulley timing mark (groove) aligns with "0" mark on timing chain cover and cylinder No. 1 is at TDC on compression stroke. Cylinder No. 1 is front cylinder at timing chain end of engine. 3. Ensure timing marks on camshaft sprockets are facing upward at 12 o'clock position. See Fig. 24 . If timing marks are not as specified, rotate crankshaft clockwise one full revolution (360 degrees) and realign crankshaft pulley timing mark (groove) with "0" mark on timing chain cover and then recheck timing mark alignment.

Fig. 24: Checking Timing Mark Alignment (ECHO & Prius) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 ENGINE PERFORMANCE On-Vehicle Adjustments - 4-Cylinder

4. With cylinder No. 1 at TDC on compression stroke, use feeler gauge to measure valve clearance between valve lifter and camshaft on specified valves. Perform STEP 1 in illustration. See Fig. 25 . Record valve clearance. 5. To check remaining valves, rotate crankshaft clockwise one full revolution (360 degrees) and realign crankshaft pulley timing mark (groove) with "0" mark on timing chain cover. Using feeler gauge, measure valve clearance between valve lifter and camshaft on specified valves. Perform STEP 2 in illustration. See Fig. 25 . Record valve clearance.

2002 ENGINE PERFORMANCE On-Vehicle Adjustments - 4-Cylinder

Fig. 25: Identifying Cylinder Numbers & Checking Valve Clearance (ECHO & Prius) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 6. Ensure valve clearance is within specification. See VALVE CLEARANCE SPECIFICATIONS (ECHO & PRIUS) table. VALVE CLEARANCE SPECIFICATIONS (ECHO & PRIUS)
(1) In. (mm) Application Intake .006-.010 (.15-.25) Exhaust .010-.014 (.25-.35) (1) Adjust valve clearance with engine cold. Verify valve clearance listed with valve clearance listed on underhood label (if available). If valve clearance on underhood label differs from valve clearance listed, use specification on underhood label.

7. If valve clearance requires adjustment, camshafts must be removed for access to valve lifters. Different thickness valve lifters are used. Rotate crankshaft clockwise (viewed from timing chain end of engine) until crankshaft pulley timing mark (groove) aligns with "0" mark on timing chain cover and cylinder No. 1 is at TDC on compression stroke. Ensure camshafts are positioned so timing marks on camshaft sprockets are facing upward at 12 o'clock position. See Fig. 24 . 8. Place reference marks on timing chain at both camshaft sprockets. See Fig. 26 . Rotate crankshaft counterclockwise 40 degrees from TDC. Remove timing chain cover plug from front of timing chain cover. See Fig. 26 . 9. Using screwdriver, rotate stopper plate on timing chain tensioner upward while rotating exhaust camshaft slightly clockwise and pushing plunger on timing chain tensioner inward. See Fig. 26 . Once plunger on timing chain tensioner is pushed inward, move stopper plate downward and install a .08.12" (2.0-3.0 mm) pin through stopper plate and into hole on timing chain tensioner to retain the plunger in retracted position. See Fig. 26 . Use tape to secure pin in place.

2002 ENGINE PERFORMANCE On-Vehicle Adjustments - 4-Cylinder

Fig. 26: Installing Reference Marks, Locating Timing Chain Cover Plug & Releasing Timing Chain Tensioner (ECHO & Prius) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 10. Manufacturer recommends removing camshaft sprockets and camshafts with timing chain still engaged with crankshaft sprocket for access to valve lifter. To remove camshafts, see appropriate article in ENGINES. Secure timing chain aside to prevent timing chain from becoming disengaged from crankshaft sprocket. DO NOT allow timing chain to become disengaged from crankshaft

2002 ENGINE PERFORMANCE On-Vehicle Adjustments - 4-Cylinder

sprocket. 11. Remove valve lifter from cylinder head. Using micrometer, measure thickness of valve lifter. See Fig. 4 . Using thickness of used valve lifter and measured clearance, determine correct thickness of valve lifter to be used for proper valve by using following equation, or using valve lifter selection charts. For intake valves, "N" (new valve lifter thickness) = "T" (used valve lifter thickness) + "A" (measured clearance) minus .0080" (.200 mm). For exhaust valves, "N" (new valve lifter thickness) = "T" (used valve lifter thickness) + "A" (measured clearance) minus .0120" (.300 mm). Valve lifters are available in 35 sizes ranging from .1992" (5.060 mm) to .2260" (5.740 mm) in increments of .0008" (.020 mm). For valve lifter selection charts, see Fig. 17 and Fig. 18 . 12. Install replacement valve lifter, camshafts and timing chain. Remove pin from timing chain tensioner. Ensure timing marks on camshaft sprockets are facing upward at 12 o'clock position and reference marks on timing chain at both camshaft sprockets are aligned when crankshaft pulley timing mark (groove) is aligned with "0" mark on timing chain cover and cylinder No. 1 is at TDC on compression stroke. See Fig. 24 and Fig. 26 . 13. Install NEW timing chain cover plug and tighten to specification. See TORQUE SPECIFICATIONS . Recheck valve clearance. Before installing valve cover and gasket, apply sealant at specified areas on cylinder head. See Fig. 15 . Install gasket, valve cover, seal washers, bolts and nuts. Tighten valve cover bolts/nuts to specification in sequence. See Fig. 27 . See TORQUE SPECIFICATIONS . To install remaining components, reverse removal procedure. Tighten ignition coil bolts to specification. See TORQUE SPECIFICATIONS .

Fig. 27: Valve Cover Bolt/Nut Tightening Sequence (ECHO & Prius) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 ENGINE PERFORMANCE On-Vehicle Adjustments - 4-Cylinder

Tacoma

1. Remove air cleaner hose along with upper cap on air cleaner and mass airflow meter. Remove intake air connector for access to valve cover. Intake air connector fits between air cleaner hose and throttle body. 2. Disconnect electrical connectors at ignition coils mounted on top of valve cover. Remove bolts and ignition coils from valve cover. Disconnect engine wiring, clamps and PCV hose for access to valve cover. Remove bolts, seal washers, valve cover and gasket. 3. Rotate crankshaft clockwise until crankshaft pulley timing mark (groove) aligns with "0" mark on timing chain cover and cylinder No. 1 is at TDC on compression stroke. Cylinder No. 1 is front cylinder at timing chain end of engine. 4. Ensure 1-dot and 2-dot timing marks on camshaft sprockets are aligned. See Fig. 28 . If timing marks are not aligned, rotate crankshaft clockwise one full revolution (360 degrees) and realign crankshaft pulley timing mark (groove) with "0" mark on timing chain cover.

Fig. 28: Aligning Camshaft Sprocket Timing Marks (Tacoma) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 5. With cylinder No. 1 at TDC on compression stroke, use feeler gauge to measure valve clearance between valve lifter and camshaft on specified valves. Perform STEP 1 in illustration. See Fig. 29 . Record valve clearance. 6. To check remaining valves, rotate crankshaft clockwise one full revolution (360 degrees) and realign

2002 ENGINE PERFORMANCE On-Vehicle Adjustments - 4-Cylinder

crankshaft pulley timing mark (groove) with "0" mark on timing chain cover. Using feeler gauge, measure valve clearance on specified valves. Perform STEP 2 in illustration. See Fig. 29 . Record valve clearance.

Fig. 29: Identifying Cylinder Numbers & Checking Valve Clearance (Tacoma) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 7. Ensure valve clearance is within specification. See VALVE CLEARANCE SPECIFICATIONS (TACOMA) table. VALVE CLEARANCE SPECIFICATIONS (TACOMA)
(1) In. (mm) Application Intake .006-.010 (.15-.25) Exhaust .010-.014 (.25-.35) (1) Adjust valve clearance with engine cold. Verify valve clearance listed with valve clearance listed on underhood label (if available). If valve clearance on underhood label differs from valve clearance listed, use specification on

2002 ENGINE PERFORMANCE On-Vehicle Adjustments - 4-Cylinder

underhood label. 8. If valve clearance requires adjustment, rotate crankshaft so camshaft lobe on valve to be adjusted is facing upward, away from valve lifter. Rotate valve lifter so notch on valve lifter is toward spark plug. 9. Valve Clearance Adjuster (SST 09248-55040) is used to remove adjusting shim. Using SST "A" of valve clearance adjuster, press valve lifter downward. See Fig. 30 . Install SST "B" between camshaft and valve lifter with side marked with No. 9 at designated position. See Fig. 30 . Remove SST "A".

Fig. 30: Removing & Installing Valve Clearance Adjusting Shim (Tacoma) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 10. Using small screwdriver and magnet, remove adjusting shim. Using micrometer, measure thickness of adjusting shim removed. Using thickness of used adjusting shim and measured clearance, determine correct thickness of adjusting shim to be used for proper valve by using the follow equation, or using adjusting shim selection charts. For intake valves, "N" (new adjusting shim thickness) = "T" (used adjusting shim thickness) + "A" (measured clearance) minus .0080" (.200 mm). For exhaust valves, "N" (new adjusting shim thickness) = "T" (used adjusting shim thickness) + "A" (measured clearance) minus .0120" (.300 mm). Adjusting shims are available in 17 sizes ranging from .0984" (2.500 mm) to .1299" (3.300 mm) in increments of .0020" (.050 mm). For adjusting shim selection charts, see Fig. 31 and Fig. 32 . 11. Install replacement adjusting shim. Recheck valve clearance. To install remaining components, reverse removal procedure. Install and tighten ignition coil bolts to specification. See TORQUE SPECIFICATIONS .

2002 ENGINE PERFORMANCE On-Vehicle Adjustments - 4-Cylinder

Fig. 31: Intake Valve Adjusting Shim Selection Chart (Tacoma) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 ENGINE PERFORMANCE On-Vehicle Adjustments - 4-Cylinder

Fig. 32: Exhaust Valve Adjusting Shim Selection Chart (Tacoma) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

IGNITION TIMING
CAMRY 1. If Toyota hand-held tester is not available, go to next step. If Toyota hand-held tester is available, connect hand-held tester to data link connector No. 3 at driver's side of instrument panel. See Fig. 41 . Start engine and warm engine to normal operating temperature. Using hand-held tester manufacturers instructions, read ignition timing with engine idling. Ignition timing should be 8-12 BTDC. Shut engine off. Remove hand-held tester. 2. If Toyota hand-held tester is not available, start engine and warm engine to normal operating temperature. Shut engine off. Remove No. 2 cylinder head cover located on top of engine, above ignition coils and valve cover. Pull out wiring harness near ignition coil so timing light lead may be connected. See Fig. 33 . Connect timing light lead to the wire in wiring harness. 3. Apply parking brake. Place transaxle in Neutral. Note location of data link connector No. 3 at driver's side of instrument panel. See Fig. 41 . Install Jumper Wire (SST 09843-18020 or SST 09843-18040) between terminals No. 4 (CG) and 13 (TC) on data link connector No. 3. See Fig. 34 . Start engine. Engine speed should increase to 1000-1300 RPM for 5 seconds and return to idle. 4. Check ignition timing with engine idling. Timing marks are located on timing chain cover, near crankshaft pulley. Ensure base timing is within specification at idle with transaxle in Neutral, and with A/C, electric cooling fan and all accessories off. See IGNITION TIMING SPECIFICATIONS table.

2002 ENGINE PERFORMANCE On-Vehicle Adjustments - 4-Cylinder

5. Remove jumper wire from data link connector No. 3. Ensure ECM controlled timing is within specification. See IGNITION TIMING SPECIFICATIONS table. Increase engine speed and check that ignition timing advances when engine speed is increased. Allow engine to idle. Shut engine off. Remove timing light. Tape wire back to wiring harness. Reinstall No. 2 cylinder head cover.

Fig. 33: Locating Wire For Connecting Timing Light (Camry & Highlander) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 ENGINE PERFORMANCE On-Vehicle Adjustments - 4-Cylinder

Fig. 34: Identifying Data Link Connector No. 3 Terminals (Camry, Camry Solara, Celica, ECHO, Highlander, MR2, Prius, RAV4 & Tacoma) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. CAMRY SOLARA 1. If Toyota hand-held tester is not available, go to next step. If Toyota hand-held tester is available, connect hand-held tester to data link connector No. 3 at driver's side of instrument panel. See Fig. 42 . Start engine and warm engine to normal operating temperature. Read ignition timing from CURRENT DATA on hand-held tester with engine idling. Ignition timing should be 8-12 BTDC. Shut engine off. Remove hand-held tester. 2. If Toyota hand-held tester is not available, start engine and warm engine to normal operating temperature. Shut engine off. Open wiring harness protector and pull out Black/White wire from wiring harness near ignition coil so timing light lead may be connected. See Fig. 35 . Connect timing light lead to the Black/White wire in wiring harness. 3. Apply parking brake. Place transaxle in Neutral. Note location of data link connector No. 3 at driver's side of instrument panel. See Fig. 42 . Install Jumper Wire (SST 09843-18020 or SST 09843-18040) between terminals No. 4 (CG) and 13 (TC) on data link connector No. 3. See Fig. 34 . Start engine. Engine speed should increase to 900-1500 RPM for 5 seconds and return to idle. 4. Check ignition timing with engine idling. Timing marks are located on timing chain cover, near crankshaft pulley. Ensure base timing is within specification at idle with transaxle in Neutral, and with A/C, electric cooling fan and all accessories off. See IGNITION TIMING SPECIFICATIONS table. 5. Remove jumper wire from data link connector No. 3. Ensure ECM controlled timing is within

2002 ENGINE PERFORMANCE On-Vehicle Adjustments - 4-Cylinder

specification. See IGNITION TIMING SPECIFICATIONS table. Allow engine to idle. Shut engine off. Remove timing light. Place wire back into wiring harness protector.

Fig. 35: Locating Wire For Connecting Timing Light (Camry Solara) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. CELICA & ECHO 1. Start engine and warm engine to normal operating temperature. Shut engine off. Connect timing light lead to cylinder No. 1. Cylinder No. 1 is front cylinder at timing chain end of engine. 2. Apply parking brake. Place transaxle in Neutral. Note location of data link connector No. 3 at driver's side of instrument panel. See Fig. 43 and Fig. 45 . Install Jumper Wire (SST 09843-18020 or SST 09843-18040) between terminals No. 4 (CG) and 13 (TC) on data link connector No. 3. See Fig. 34 . 3. Start engine. Check ignition timing with engine idling. Timing marks are located on timing chain cover, near crankshaft pulley. Ensure base timing is within specification at idle with transaxle in Neutral, and with A/C and all accessories off. See IGNITION TIMING SPECIFICATIONS table. Shut engine off. Remove jumper wire and timing light. COROLLA 1. Start engine and warm engine to normal operating temperature. Shut engine off. 2. Connect timing light lead to Black/White wire at ignition coil for cylinder No. 1. See Fig. 36 . Cylinder No. 1 is front cylinder at timing chain end of engine. 3. Install Jumper Wire (SST 09843-18020 or SST 09843-18040) between terminals TE1 and E1 on data

2002 ENGINE PERFORMANCE On-Vehicle Adjustments - 4-Cylinder

link connector No. 1. See Fig. 37 . Data link connector No. 1 is located at driver's side of engine compartment, near strut tower. 4. Apply parking brake. Place transaxle in Neutral. Start engine. Engine speed should increase to 10001300 RPM for 5 seconds and return to idle. 5. Check ignition timing with engine idling. Timing marks are located on timing chain cover, near crankshaft pulley. Ensure base timing is within specification at idle with transaxle in Neutral, and with A/C and all accessories off. See IGNITION TIMING SPECIFICATIONS table. 6. Remove jumper wire from data link connector No. 1. Ensure ECM controlled timing is within specification. See IGNITION TIMING SPECIFICATIONS table. Shut engine off. Remove timing light.

Fig. 36: Connecting Timing Light (Corolla) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 ENGINE PERFORMANCE On-Vehicle Adjustments - 4-Cylinder

Fig. 37: Installing Jumper Wire Between Data Link Connector No. 1 Terminals (Corolla) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. HIGHLANDER 1. If Toyota hand-held tester is not available, go to next step. If Toyota hand-held tester is available, connect hand-held tester to data link connector No. 3 at driver's side of instrument panel. See Fig. 46 . Start engine and warm engine to normal operating temperature. Using hand-held tester manufacturers instructions, read ignition timing with engine idling. Ignition timing should be 8-12 BTDC. Shut engine off. Remove hand-held tester. 2. If Toyota hand-held tester is not available, start engine and warm engine to normal operating temperature. Shut engine off. Remove No. 2 cylinder head cover located on top of engine, above ignition coils and valve cover. Pull out wiring harness near ignition coil so timing light lead may be connected. See Fig. 33 . Connect timing light lead to the wire in wiring harness. 3. Apply parking brake. Place transaxle in Neutral. Note location of data link connector No. 3 at driver's side of instrument panel. See Fig. 46 . Install Jumper Wire (SST 09843-18020 or SST 09843-18040) between terminals No. 4 (CG) and 13 (TC) on data link connector No. 3. See Fig. 34 . Start engine. Engine speed should increase to 1000-1300 RPM for 5 seconds and return to idle. 4. Check ignition timing with engine idling. Timing marks are located on timing chain cover, near crankshaft pulley. Ensure base timing is within specification at idle with transaxle in Neutral, and with A/C, electric cooling fan and all accessories off. See IGNITION TIMING SPECIFICATIONS table. 5. Remove jumper wire from data link connector No. 3. Ensure ECM controlled timing is within specification. See IGNITION TIMING SPECIFICATIONS table. Increase engine speed and check that ignition timing advances when engine speed is increased. Allow engine to idle. Shut engine off.

2002 ENGINE PERFORMANCE On-Vehicle Adjustments - 4-Cylinder

Remove timing light. Tape wire back to wiring harness. Reinstall No. 2 cylinder head cover. MR2 1. Start engine and warm engine to normal operating temperature. Shut engine off. Remove cover from junction block No. 1 and connect timing light lead to Black/Red wire. See Fig. 38 . Junction block No. 1 is located at driver's side rear corner of engine compartment, just in front of strut tower. 2. Apply parking brake. Place transaxle in Neutral. Note location of data link connector No. 3 at driver's side of instrument panel. See Fig. 47 . Install Jumper Wire (SST 09843-18020 or SST 09843-18040) between terminals No. 4 (CG) and 13 (TC) on data link connector No. 3. See Fig. 34 . Start engine. Engine speed should increase to 1000-1500 RPM for 5 seconds and return to idle. 3. Check ignition timing with engine idling. Timing marks are located on timing chain cover, near crankshaft pulley. Ensure base timing is within specification at idle with transaxle in Neutral, and with A/C, electric cooling fan and all accessories off. See IGNITION TIMING SPECIFICATIONS table. 4. Remove jumper wire from data link connector No. 3. Ensure ECM controlled timing is within specification. See IGNITION TIMING SPECIFICATIONS table. Shut engine off. Remove timing light. Reinstall cover on junction block No. 1.

Fig. 38: Connecting Timing Light (MR2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 ENGINE PERFORMANCE On-Vehicle Adjustments - 4-Cylinder

PRIUS WARNING: Read service precautions before proceeding with service procedure. See SERVICE PRECAUTIONS . 1. Connect timing light lead to cylinder No. 1. Cylinder No. 1 is front cylinder at timing chain end of engine. On this model, the engine is shut off when engine is at normal operating temperature and battery is fully charged and A/C is not turned on. It is necessary to put transit in inspection mode so engine will run continuously when checking ignition timing. To put transit in inspection mode, perform the following steps within 60 seconds: Ensure ignition is off and then turn ignition on. Ensure transaxle is in Park and then fully depress accelerator pedal 2 times. Place transaxle in Neutral and then fully depress accelerator pedal 2 times. Place transaxle back in Park and then fully depress accelerator pedal 2 times. Check that master warning light on instrument cluster at center of instrument panel is flashing to indicate inspection mode operation. See Fig. 39 . Master warning light may also be referred to as hybrid system error warning light. Turn ignition switch to START position to start engine. Engine will now start and run continuously. Warm engine to normal operating temperature. 2. Ensure transaxle is in Park. Note location of data link connector No. 3 at driver's side of instrument panel. See Fig. 48 . Install Jumper Wire (SST 09843-18020 or SST 09843-18040) between terminals No. 4 (CG) and 13 (TC) on data link connector No. 3. See Fig. 34 . 3. Check ignition timing with engine idling. Timing marks are located on timing chain cover, near crankshaft pulley. Ensure base timing is within specification at idle with transaxle in Park and with A/C and all accessories off. See IGNITION TIMING SPECIFICATIONS table. Shut engine off. Remove jumper wire and timing light.

Fig. 39: Locating Master Warning Light (Prius) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 ENGINE PERFORMANCE On-Vehicle Adjustments - 4-Cylinder

RAV4 1. Start engine and warm engine to normal operating temperature. Shut engine off. Connect timing light lead to Black/White wire in wiring harness near air cleaner assembly. See Fig. 40 . 2. Apply parking brake. Place transaxle in Neutral. Note location of data link connector No. 3 at driver's side of instrument panel. See Fig. 49 . Install Jumper Wire (SST 09843-18020 or SST 09843-18040) between terminals No. 4 (CG) and 13 (TC) on data link connector No. 3. See Fig. 34 . Start engine. Engine speed should increase to 900-1500 RPM for 5 seconds and return to idle. 3. Check ignition timing with engine idling. Timing marks are located on timing chain cover, near crankshaft pulley. Ensure base timing is within specification at idle with transaxle in Neutral, and with A/C, electric cooling fan and all accessories off. See IGNITION TIMING SPECIFICATIONS table. 4. Remove jumper wire from data link connector No. 3. Ensure ECM controlled timing is within specification. See IGNITION TIMING SPECIFICATIONS table. Shut engine off. Remove timing light.

Fig. 40: Connecting Timing Light (RAV4) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 ENGINE PERFORMANCE On-Vehicle Adjustments - 4-Cylinder

TACOMA 1. Start engine and warm engine to normal operating temperature. Shut engine off. Connect timing light lead to Black/Red wire at ignition coil for cylinder No. 1. Cylinder No. 1 is front cylinder at timing chain end of engine. 2. Apply parking brake. Place transmission in Neutral. Note location of data link connector No. 3 at driver's side of instrument panel. See Fig. 50 . Install Jumper Wire (SST 09843-18020 or SST 0984318040) between terminals No. 4 (CG) and 13 (TC) on data link connector No. 3. See Fig. 34 . Start engine. Engine speed should increase to about 1000 RPM for 5 seconds and return to idle. 3. Check ignition timing with engine idling. Timing marks are located on timing chain cover, near crankshaft pulley. Ensure base timing is within specification at idle with transmission in Neutral, and with A/C and all accessories off. See IGNITION TIMING SPECIFICATIONS table. 4. Remove jumper wire from data link connector No. 3. Ensure ECM controlled timing is within specification. See IGNITION TIMING SPECIFICATIONS table. Shut engine off. Remove timing light. IGNITION TIMING SPECIFICATIONS (Degrees BTDC @ Idle)(1) ECM Controlled Application Base Timing Timing (2) 8-12 (3) 5-15 Camry & Camry Solara Celica (2) 10-18 (4) 1.8L (1ZZFE) (2) 8-12 (4) 1.8L (2ZZGE) (5) 8-12 (6) 6-15 Corolla ECHO Highlander MR2 Prius (7) RAV4 Tacoma
(2) 8-12 (2) 8-12 (2) 8-12 (2) 7-15 (2) 8-12 (2) 3-7 (4) (3) 5-15 (3) 6-15 (4) (3) 5-15 (3) 4-17

(1) Check with engine at normal operating temperature,

transaxle/transmission in Neutral (except Prius, in Park on Prius), parking brake applied, and A/C and all accessories off. (2) With Jumper Wire (SST 09843-18020 or SST 0984318040) installed between terminals No. 4 (CG) and 13 (TC) CG on data link connector No. 3. (3) With jumper wire removed from data link connector No. 3.

2002 ENGINE PERFORMANCE On-Vehicle Adjustments - 4-Cylinder

(4) Information is not available from manufacturer. (5) With Jumper Wire (SST 09843-18020 or SST 09843-

18040) installed between terminals TE1 and E1 on data link connector No. 1. (6) With jumper wire removed from data link connector No. 1. (7) Read service precautions before proceeding with service procedure. See SERVICE PRECAUTIONS . Check with transit in inspection mode and transaxle in Park.

Fig. 41: Locating Data Link Connector No. 3 (Camry) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 ENGINE PERFORMANCE On-Vehicle Adjustments - 4-Cylinder

Fig. 42: Locating Data Link Connector No. 3 (Camry Solara) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 ENGINE PERFORMANCE On-Vehicle Adjustments - 4-Cylinder

Fig. 43: Locating Data Link Connector No. 3 (Celica) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 ENGINE PERFORMANCE On-Vehicle Adjustments - 4-Cylinder

Fig. 44: Locating Data Link Connector No. 3 (Corolla) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 ENGINE PERFORMANCE On-Vehicle Adjustments - 4-Cylinder

Fig. 45: Locating Data Link Connector No. 3 (ECHO) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 ENGINE PERFORMANCE On-Vehicle Adjustments - 4-Cylinder

Fig. 46: Locating Data Link Connector No. 3 (Highlander) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 ENGINE PERFORMANCE On-Vehicle Adjustments - 4-Cylinder

Fig. 47: Locating Data Link Connector No. 3 (MR2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 ENGINE PERFORMANCE On-Vehicle Adjustments - 4-Cylinder

Fig. 48: Locating Data Link Connector No. 3 (Prius) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 ENGINE PERFORMANCE On-Vehicle Adjustments - 4-Cylinder

Fig. 49: Locating Data Link Connector No. 3 (RAV4) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 ENGINE PERFORMANCE On-Vehicle Adjustments - 4-Cylinder

Fig. 50: Locating Data Link Connector No. 3 (Tacoma) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

IDLE SPEED & MIXTURE

NOTE: CAMRY 1. Idle speed is controlled by Engine Control Module (ECM) and is not adjustable. Check idle speed with engine at normal operating temperature, transaxle in Neutral, parking brake applied, air cleaner and all air intake hoses installed, all vacuum hoses installed, electronic fuel injection system wiring connectors properly installed, ignition timing properly set, electric cooling fan off, and A/C and all accessories off. 2. If Toyota hand-held tester is available, go to next step. If Toyota hand-held tester is not available, go to step 5 . 3. Start engine and warm engine to normal operating temperature. Shut engine off. Connect Toyota hand-held tester to data link connector No. 3 at driver's side of instrument panel. See Fig. 41 . Handheld tester is used to read engine RPM. Apply parking brake. Place transaxle in Neutral. Start engine and allow engine to idle while noting idle speed. Ensure idle speed is within specification. See IDLE SPEED SPECIFICATIONS table. Shut engine off. Remove hand-held tester. 4. If idle speed is not within specification, check air intake system. If air intake system is okay, check throttle body. See IDLE CONTROL SYSTEMS in SYSTEM & COMPONENT TESTING - 4CYLINDER article. 5. Start engine and warm engine to normal operating temperature. Shut engine off. Note location of data link connector No. 3 at driver's side of instrument panel. See Fig. 41 . Using Jumper Wire (SST Mixture adjustment is not possible on any model.

2002 ENGINE PERFORMANCE On-Vehicle Adjustments - 4-Cylinder

09843-18020 or SST 09843-18040), connect tachometer lead to terminal No. 9 (TAC) on data link connector No. 3. See Fig. 34 . Apply parking brake. Place transaxle in Neutral. Start engine and allow engine to idle while noting idle speed. Ensure idle speed is within specification. See IDLE SPEED SPECIFICATIONS table. Shut engine off. Disconnect tachometer. 6. If idle speed is not within specification, check air intake system. If air intake system is okay, check throttle body. See IDLE CONTROL SYSTEMS in SYSTEM & COMPONENT TESTING - 4CYLINDER article. CAMRY SOLARA 1. Idle speed is controlled by Engine Control Module (ECM) and is not adjustable. Check idle speed with engine at normal operating temperature, transaxle in Neutral, parking brake applied, air cleaner and all air intake hoses installed, all vacuum hoses installed, electronic fuel injection system wiring connectors properly installed, ignition timing properly set, electric cooling fan off, and A/C and all accessories off. 2. Start engine and warm engine to normal operating temperature. Shut engine off. Connect Toyota hand-held tester to data link connector No. 3 at driver's side of instrument panel. See Fig. 42 . Handheld tester is used to read engine RPM. 3. Apply parking brake. Place transaxle in Neutral. Start engine and increase engine speed to 2500 RPM for 90 seconds and then allow engine to idle while reading idle speed from CURRENT DATA on hand-held tester. Ensure idle speed is within specification. See IDLE SPEED SPECIFICATIONS table. Shut engine off. Remove hand-held tester. 4. If idle speed is not within specification, check air intake system. If air intake system is okay, check throttle body. See IDLE CONTROL SYSTEMS in SYSTEM & COMPONENT TESTING - 4CYLINDER article. CELICA, COROLLA, ECHO, RAV4 & TACOMA 1. Idle speed is controlled by Engine Control Module (ECM) and is not adjustable. Check idle speed with engine at normal operating temperature, transmission/transaxle in Neutral, parking brake applied, air cleaner and all air intake hoses installed, all vacuum hoses installed, electronic fuel injection system wiring connectors properly installed, ignition timing properly set, electric cooling fan off (if equipped), and A/C and all accessories off. 2. Start engine and warm engine to normal operating temperature. Shut engine off. Connect Toyota hand-held tester or scan tool to data link connector No. 3 at driver's side of instrument panel. See Fig. 43 -Fig. 50 . Hand-held tester or scan tool is used to read engine RPM. 3. Apply parking brake. Place transmission/transaxle in Neutral. Start engine and maintain engine at 2500 RPM for 90 seconds and then allow engine to idle while noting idle speed. Ensure idle speed is within specification. See IDLE SPEED SPECIFICATIONS table. Shut engine off. Remove handheld tester or scan tool. 4. If idle speed is not within specification, check Idle Air Control (IAC) valve, wiring and Engine Control Module (ECM), and air intake system. See IDLE CONTROL SYSTEMS in SYSTEM & COMPONENT TESTING - 4-CYLINDER article. HIGHLANDER 1. Idle speed is controlled by Engine Control Module (ECM) and is not adjustable. Check idle speed with engine at normal operating temperature, transaxle in Neutral, parking brake applied, air cleaner and all air intake hoses installed, all vacuum hoses installed, electronic fuel injection system wiring

2002 ENGINE PERFORMANCE On-Vehicle Adjustments - 4-Cylinder

2. 3.

4.

5.

6.

7.

8.

connectors properly installed, ignition timing properly set, electric cooling fan off, and A/C and all accessories off. If Toyota hand-held tester is available, go to next step. If Toyota hand-held tester is not available, go to step 6 . Start engine and warm engine to normal operating temperature. Shut engine off. Connect Toyota hand-held tester to data link connector No. 3 at driver's side of instrument panel. See Fig. 46 . Handheld tester is used to read engine RPM. Apply parking brake. Place transaxle in Neutral. Start engine and allow engine to idle while noting idle speed. Ensure idle speed is within specification. See IDLE SPEED SPECIFICATIONS table. Shut engine off. Remove hand-held tester. If idle speed is not within specification, check air intake system. If air intake system is okay, check throttle body. See IDLE CONTROL SYSTEMS in SYSTEM & COMPONENT TESTING - 4CYLINDER article. Start engine and warm engine to normal operating temperature. Shut engine off. Note location of data link connector No. 3 at driver's side of instrument panel. See Fig. 46 . Using Jumper Wire (SST 09843-18020 or SST 09843-18040), connect tachometer lead to terminal No. 9 (TAC) on data link connector No. 3. See Fig. 34 . Apply parking brake. Place transaxle in Neutral. Start engine and allow engine to idle while noting idle speed. Ensure idle speed is within specification. See IDLE SPEED SPECIFICATIONS table. Shut engine off. Disconnect tachometer. If idle speed is not within specification, check air intake system. If air intake system is okay, check throttle body. See IDLE CONTROL SYSTEMS in SYSTEM & COMPONENT TESTING - 4CYLINDER article.

MR2 1. Idle speed is controlled by Engine Control Module (ECM) and is not adjustable. Check idle speed with engine at normal operating temperature, transaxle in Neutral, parking brake applied, air cleaner and all air intake hoses installed, all vacuum hoses installed, electronic fuel injection system wiring connectors properly installed, ignition timing properly set, electric cooling fan off (if equipped), and A/C and all accessories off. 2. Start engine and warm engine to normal operating temperature. Shut engine off. Connect Toyota hand-held tester or scan tool to data link connector No. 3 at driver's side of instrument panel. See Fig. 47 . Hand-held tester or scan tool is used to read engine RPM. 3. Apply parking brake. Place transaxle in Neutral. Start engine and maintain engine at 2500 RPM for 90 seconds and then allow engine to idle while noting idle speed. Ensure idle speed is within specification. See IDLE SPEED SPECIFICATIONS table. Shut engine off. Remove hand-held tester or scan tool. 4. There are 2 types of throttle bodies and idle control systems used depending on type of transaxle used. On models with a standard type manual transaxle in which the driver operates the clutch and shifts the transaxle, a standard type Idle Air Control (IAC) valve used. On this model, if idle speed is not within specification, check Idle Air Control (IAC) valve, wiring and Engine Control Module (ECM), and air intake system. See IDLE CONTROL SYSTEMS in SYSTEM & COMPONENT TESTING - 4CYLINDER article. On models with a sequential manual transaxle, the transaxle is electronically controlled and clutch is operated and transaxle is shifted hydraulically by moving shift lever forward or backward. Sequential manual transaxle may be identified by shift lever pattern which consists of "R", "N", "S" and "+" in place of conventional type shift lever pattern and no clutch pedal is used. On this model, if idle speed is not within specification, check air intake system. If air intake system is okay, check throttle body. See IDLE CONTROL SYSTEMS in SYSTEM & COMPONENT

2002 ENGINE PERFORMANCE On-Vehicle Adjustments - 4-Cylinder

TESTING - 4-CYLINDER article. PRIUS WARNING: Read service precautions before proceeding with service procedure. See SERVICE PRECAUTIONS . 1. Idle speed is controlled by Engine Control Module (ECM) and is not adjustable. Check idle speed with engine at normal operating temperature, transaxle in Park, transit in inspection mode, air cleaner and all air intake hoses installed, all vacuum hoses installed, electronic fuel injection system wiring connectors properly installed, ignition timing properly set and A/C and all accessories off. 2. On this model, the engine is shut off when engine is at normal operating temperature and battery is fully charged and A/C is not turned on. It is necessary to put transit in inspection mode so engine will run continuously when checking idle speed. To put transit in inspection mode, perform the following steps within 60 seconds: Ensure ignition is off and then turn ignition on. Ensure transaxle is in Park and then fully depress accelerator pedal 2 times. Place transaxle in Neutral and then fully depress accelerator pedal 2 times. Place transaxle back in Park and then fully depress accelerator pedal 2 times. Check that master warning light on instrument cluster at center of instrument panel is flashing to indicate inspection mode operation. See Fig. 39 . Master warning light may also be referred to as hybrid system error warning light. Turn ignition switch to START position to start engine. Engine will now start and run continuously. 3. Ensure transaxle is in Park. Warm engine to normal operating temperature. Connect Toyota hand-held tester to data link connector No. 3 at driver's side of instrument panel. See Fig. 48 . Hand-held tester is used to read engine RPM. 4. Maintain engine at 2250 RPM for 90 seconds and then allow engine to idle while noting idle speed. Ensure idle speed is within specification. See IDLE SPEED SPECIFICATIONS table. Shut engine off. Remove hand-held tester. 5. If idle speed is not within specification, check air intake system. If air intake system is okay, check throttle body. See IDLE CONTROL SYSTEMS in SYSTEM & COMPONENT TESTING - 4CYLINDER article. IDLE SPEED SPECIFICATIONS (1) Application Camry A/T M/T Camry Solara A/T M/T Celica 1.8L (1ZZ-FE) A/T M/T 1.8L (2ZZ-GE)

RPM 610-710 650-750 600-700 650-750

700-800 650-750

2002 ENGINE PERFORMANCE On-Vehicle Adjustments - 4-Cylinder

A/T M/T Corolla ECHO A/T M/T Highlander MR2

700-800 750-850 650-750 650-750 600-700 600-700 650-750 950-1050

Prius (2) RAV4 & 650-750 Tacoma (1) Check with engine at normal operating temperature, transaxle/transmission in Neutral (except Prius, in Park on Prius), parking brake applied, air cleaner and all air intake hoses installed, all vacuum hoses installed, electronic fuel injection system wiring connectors properly installed, ignition timing properly set, electric cooling fan off (if equipped), and A/C and all accessories off. (2) Read service precautions before proceeding with service procedure. See SERVICE PRECAUTIONS . Check with transit in inspection mode and transaxle in Park.

THROTTLE POSITION SENSOR

CAMRY & CAMRY SOLARA 1. Manufacturer does not list procedure for Throttle Position (TP) sensor adjustment. Only information available is for checking resistance of TP sensor. 2. Disconnect 6-pin electrical connector from throttle body for TP sensor. Using ohmmeter, check resistance between VC and E2 terminals on throttle body for TP sensor. See Fig. 51 . Replace throttle body assembly if resistance is not within specification. SeeTHROTTLE POSITION SENSOR RESISTANCE table. CELICA, COROLLA, ECHO & HIGHLANDER 1. Manufacturer does not list procedure for Throttle Position (TP) sensor adjustment. Only information available is for checking resistance of TP sensor. 2. Disconnect electrical connector from TP sensor. Note electrical terminals on TP sensor. See Fig. 52 Fig. 55 . 3. Using ohmmeter, check resistance between specified terminals in relation to throttle position. See THROTTLE POSITION SENSOR RESISTANCE table. Replace components as necessary if resistance is not within specification.

2002 ENGINE PERFORMANCE On-Vehicle Adjustments - 4-Cylinder

MR2 1. There are 2 types of throttle bodies and Throttle Position (TP) sensors, depending on type of transaxle used. On models with standard type manual transaxle, the driver operates the clutch and shifts the transaxle. On models with sequential manual transaxle, transaxle is electronically controlled and clutch is operated and transaxle is shifted hydraulically by moving shift lever forward or backward. Sequential manual transaxle may be identified by shift lever pattern which consists of "R", "N", "S" and "+" in place of conventional type shift lever pattern and no clutch pedal is used. On this model, a different type TP sensor is used. On all models, manufacturer does not list procedure for TP sensor adjustment. Only information available is for checking resistance of TP sensor. 2. On models with sequential manual transaxle, it may be necessary to remove throttle body for access to electrical connector at TP sensor. If necessary to remove throttle body, see THROTTLE BODY under FUEL SYSTEMS in REMOVAL, OVERHAUL & INSTALLATION - 4-CYLINDER article. On all models, disconnect electrical connector from TP sensor. Note electrical terminals on TP sensor. See Fig. 56 and Fig. 57 . 3. On models with standard type manual transaxle, using ohmmeter, check resistance between specified terminals in relation to throttle position. See THROTTLE POSITION SENSOR RESISTANCE table. Replace components as necessary if resistance is not within specification. 4. On models with sequential manual transaxle, using ohmmeter, check resistance between VC and E2 terminals on TP sensor. Replace components as necessary if resistance is not within specification. See THROTTLE POSITION SENSOR RESISTANCE table. PRIUS WARNING: Read service precautions before proceeding with service procedure. See SERVICE PRECAUTIONS . 1. Manufacturer does not list procedure for Throttle Position (TP) sensor adjustment. Only information available is for checking resistance of TP sensor. 2. Disconnect electrical connector from TP sensor. Note electrical terminals on TP sensor. See Fig. 58 . Using ohmmeter, check resistance between VC and E2 terminals on TP sensor. Replace TP sensor if resistance is not within specification. See THROTTLE POSITION SENSOR RESISTANCE table. RAV4 1. Manufacturer does not list procedure for Throttle Position (TP) sensor adjustment. Only information available is for checking resistance of TP sensor. 2. Disconnect electrical connector from TP sensor. Note electrical terminals on TP sensor. See Fig. 59 . Using ohmmeter, check resistance between specified terminals in relation to throttle position. See THROTTLE POSITION SENSOR RESISTANCE table. Replace components as necessary if resistance is not within specification. TACOMA 1. Manufacturer does not list procedure for Throttle Position (TP) sensor adjustment. Only information available is for checking resistance of TP sensor. 2. Disconnect electrical connector from TP sensor. Note electrical terminals on TP sensor. See Fig. 60 . Apply vacuum to throttle opener located on throttle body. See Fig. 60 .

2002 ENGINE PERFORMANCE On-Vehicle Adjustments - 4-Cylinder

3. Using ohmmeter, check resistance between specified terminals in relation to throttle position. See THROTTLE POSITION SENSOR RESISTANCE table. Replace components as necessary if resistance is not within specification. THROTTLE POSITION SENSOR RESISTANCE Application Throttle Position Camry & Camry Solara .... Celica, Corolla & ECHO Fully Open Highlander Fully Open MR2 Models With Standard Type Manual Transaxle Fully Open Models With Sequential Manual Transaxle Prius RAV4 Fully Open Tacoma (2) Fully Open
(1) Resistance at 68F (20C). (2) Apply vacuum to throttle opener before checking TP sensor.

Terminals VC & E2 VTA & E2 VTA & E2 VC & E2 VTA & E2 VTA & E2 VC & E2 VTA & E2 VTA & E2 VC & E2 VC & E2 VC & E2 VTA & E2 VTA & E2 VC & E2 VTA & E2 VTA & E2 VC & E2

Ohms
(1) 1200-3200

Fully Closed

Fully Closed

200-5700 2000-10,200 2500-5900 200-5700 2000-10,200 2500-5000 200-5700 2000-10,200 2500-5900

(1) 1200-3200 (1) 1200-3200

Fully Closed

.... .... Fully Closed

Fully Closed

200-5700 2000-10,200 2500-5900 200-5700 2000-10,200 2500-5900

2002 ENGINE PERFORMANCE On-Vehicle Adjustments - 4-Cylinder

Fig. 51: Identifying Throttle Position Sensor Terminals (Camry & Camry Solara) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 ENGINE PERFORMANCE On-Vehicle Adjustments - 4-Cylinder

Fig. 52: Identifying Throttle Position Sensor Terminals (Celica) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 ENGINE PERFORMANCE On-Vehicle Adjustments - 4-Cylinder

Fig. 53: Identifying Throttle Position Sensor Terminals (Corolla) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 54: Identifying Throttle Position Sensor Terminals (ECHO) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 ENGINE PERFORMANCE On-Vehicle Adjustments - 4-Cylinder

Fig. 55: Identifying Throttle Position Sensor Terminals (Highlander) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 ENGINE PERFORMANCE On-Vehicle Adjustments - 4-Cylinder

Fig. 56: Identifying Throttle Position Sensor Terminals (MR2 With Standard Type Manual Transaxle) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 ENGINE PERFORMANCE On-Vehicle Adjustments - 4-Cylinder

Fig. 57: Identifying Throttle Position Sensor Terminals (MR2 With Sequential Manual Transaxle) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 ENGINE PERFORMANCE On-Vehicle Adjustments - 4-Cylinder

Fig. 58: Identifying Throttle Position Sensor Terminals (Prius) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 ENGINE PERFORMANCE On-Vehicle Adjustments - 4-Cylinder

Fig. 59: Identifying Throttle Position Sensor Terminals (RAV4) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 60: Identifying Throttle Position Sensor Terminals & Locating Throttle Opener (Tacoma) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 ENGINE PERFORMANCE On-Vehicle Adjustments - 4-Cylinder

THROTTLE OPENER
THROTTLE OPENER ADJUSTMENT
Tacoma

1. Start engine and warm engine to normal operating temperature. Ensure idle speed is within specification. See IDLE SPEED & MIXTURE . 2. With engine idling, disconnect and plug vacuum hose at throttle opener. See Fig. 61 . Note engine speed with vacuum hose disconnected from throttle opener. Engine speed should be 1200-1500 RPM. 3. If engine speed is not within specification, throttle opener is nonadjustable and throttle body must be replaced. Shut engine off. Reinstall vacuum hose on throttle opener. Start engine and ensure engine returns to proper idle speed. If necessary to replace throttle body, see THROTTLE BODY under FUEL SYSTEMS in REMOVAL, OVERHAUL & INSTALLATION - 4-CYLINDER article.

Fig. 61: Locating Throttle Opener & Disconnecting Vacuum Hose (Tacoma) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

MISCELLANEOUS CONTROLS
PARK/NEUTRAL POSITION SWITCH For adjustment of Park/Neutral Position (PNP) switch, see PARK/NEUTRAL POSITION SWITCH under ENGINE SENSORS & SWITCHES in REMOVAL, OVERHAUL & INSTALLATION - 4-CYLINDER article.

2002 ENGINE PERFORMANCE On-Vehicle Adjustments - 4-Cylinder

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS Application Timing Chain Cover Plug ECHO & Prius Ventilation Pipe Bolt/Nut Celica 1.8L 2ZZ-GE Wheel Lug Nut Camry & Highlander Ignition Coil Bolt Camry, Camry Solara, Celica, Corolla, ECHO, Highlander, MR2, Prius & RAV4 Tacoma Valve Cover Bolt Or Nut Camry & Camry Solara Celica 1.8L 1ZZ-FE 1.8L 2ZZ-GE Corolla ECHO Highlander MR2 Prius RAV4 Tacoma
(1) Tighten nuts to 88 INCH lbs. (9.9 N.m) and bolt to 18 ft. lbs. (24 N.m). (2) Tighten bolts/nuts with washer to 80 INCH lbs. (9.0 N.m). Tighten bolts/nuts without washer to

Ft. Lbs. (N.m) 11 (15.0)

(1)

76 (103) INCH Lbs. (N.m) 80 (9.0) 66 (7.5) 97 (11.0)

(2)

88 (9.9)
(3) (4) 88 (9.9) (5) (3) (4) 88 (9.9)

97 (11.0)
(6)

97 INCH lbs. (11.0 N.m).

(3) Tighten bolts/nuts with washer to 80 INCH lbs. (9.0 N.m). Tighten bolts/nuts without washer to

97 INCH lbs. (11.0 N.m). Tighten bolts/nuts to specification in sequence. See Fig. 16 . (4) Tighten bolts/nuts to specification in sequence. See Fig. 27 .
(5) Tighten bolts/nuts to specification. See Fig. 6 . (6) Information is not available from manufacturer.

2002 ENGINE PERFORMANCE Toyota Introduction

2002 ENGINE PERFORMANCE Toyota Introduction 2002 MODEL COVERAGE MODEL ENGINE Avalon Camry ..... Camry Solara ..... Celica ..... Corolla ECHO Highlander ..... Land Cruiser MR2 Prius (4) RAV4 Sequoia Sienna Tacoma ..... ..... Tundra ..... 4Runner 3.0L V6 (1MZ-FE) 2.4L 4-Cyl. (2AZFE) 3.0L V6 (1MZ-FE) 2.4L 4-Cyl. (2AZFE) 3.0L V6 (1MZ-FE) 1.8L 4-Cyl. (1ZZFE) 1.8L 4-Cyl. (2ZZGE) 1.8L 4-Cyl. (1ZZFE) 1.5L 4-Cyl. (1NZFE) 2.4L 4-Cyl. (2AZFE) 3.0L V6 (1MZ-FE) 4.7L V8 (2UZ-FE) 1.8L 4-Cyl. (1ZZFE) 1.5L 4-Cyl. (1NZFXE) 2.0L 4-Cyl. (1AZFE) 4.7L V8 (2UZ-FE) 3.0L V6 (1MZ-FE) 2.4L 4-Cyl. (2RZFE) 2.7L 4-Cyl. (3RZFE) 3.4L V6 (5VZ-FE) 3.4L V6 (5VZ-FE) 4.7L V8 (2UZ-FE) 3.4L V6 (5VZ-FE)

ENGINE ID
(1)

FUEL SYSTEM IGNITION SYSTEM

(2)

F D F D F R Y R T D F T R B K T F L M N N T N

SFI SFI SFI SFI SFI SFI SFI SFI SFI SFI SFI SFI SFI SFI SFI SFI SFI SFI SFI SFI SFI SFI SFI

DIS (3) DIS (3) DIS (3) DIS (3) DIS (3) DIS (3) DIS (3) DIS (3) DIS (3) DIS (3) DIS (3) DIS (3) DIS (3) DIS (3) DIS (3) DIS (3) DIS (3) DIS (3) DIS (3) DIS (3) DIS (3) DIS (3)

DIS (3) (1) Engine may be identified by Vehicle Identification Number (VIN). VIN is located on VIN plate on driver's side of instrument panel. See Fig. 2 -Fig. 4 . Engine serial number is stamped on

2002 ENGINE PERFORMANCE Toyota Introduction

cylinder block. See Fig. 5 -Fig. 15 . (2) Fuel injection system is a Sequential Multiport Fuel Injection (SFI) system.
(3) Application uses a Distributorless Ignition System (DIS). (4) This is the hybrid vehicle which uses a gasoline engine along with the AC electric motor for

vehicle operation. Only service procedures for the gasoline engine are covered.

Fig. 1: VIN Definition Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

MODEL/YEAR VIN CODE APPLICATIONS

MODEL/YEAR VIN CODE APPLICATION VIN Code Y 1 2 Model Year 2000 2001 2002

2002 ENGINE PERFORMANCE Toyota Introduction

Fig. 2: Locating Typical Vehicle Identification Number Plate & Certification Label (Avalon, Camry, Camry Solara, Celica, Corolla, ECHO, MR2 & Prius) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 ENGINE PERFORMANCE Toyota Introduction

Fig. 3: Locating Typical Vehicle Identification Number Plate & Certification Label (Highlander, Land Cruiser, RAV4, Sequoia, Tacoma, Tundra & 4Runner) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 ENGINE PERFORMANCE Toyota Introduction

Fig. 4: Locating Vehicle Identification Number Plate & Certification Label (Sienna) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

ENGINE SERIAL NUMBER LOCATION

Engine serial number is located on cylinder block. See Fig. 5 -Fig. 15 .

2002 ENGINE PERFORMANCE Toyota Introduction

Fig. 5: Locating 1.5L Engine Serial Number (ECHO) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 ENGINE PERFORMANCE Toyota Introduction

Fig. 6: Locating 1.5L Engine Serial Number (Prius) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 ENGINE PERFORMANCE Toyota Introduction

2002 ENGINE PERFORMANCE Toyota Introduction

Fig. 7: Locating 1.8L Engine Serial Number (Celica) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 8: Locating 1.8L Engine Serial Number (Corolla) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 ENGINE PERFORMANCE Toyota Introduction

Fig. 9: Locating 1.8L Engine Serial Number (MR2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 ENGINE PERFORMANCE Toyota Introduction

Fig. 10: Locating 2.0L Engine Serial Number (RAV4) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 ENGINE PERFORMANCE Toyota Introduction

Fig. 11: Locating 2.4L Engine Serial Number (Camry, Camry Solara & Highlander) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 ENGINE PERFORMANCE Toyota Introduction

Fig. 12: Locating 2.4L & 2.7L Engine Serial Number (Tacoma) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 ENGINE PERFORMANCE Toyota Introduction

Fig. 13: Locating 3.0L Engine Serial Number (Avalon, Camry, Camry Solara, Highlander & Sienna) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 ENGINE PERFORMANCE Toyota Introduction

Fig. 14: Locating 3.4L Engine Serial Number (Tacoma, Tundra & 4Runner) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 ENGINE PERFORMANCE Toyota Introduction

Fig. 15: Locating 4.7L Engine Serial Number (Land Cruiser, Sequoia & Tundra) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

1968-2003 ENGINE PERFORMANCE Emission Applications - Toyota (1968-2003)

1968-2003 ENGINE PERFORMANCE Emission Applications - Toyota (1968-2003)

EMISSION APPLICATIONS
1968-2003 TOYOTA Year, Model, Engine & Fuel System All Engines Carb. 1970 Except 8R-C & F 1.8L Carb. 8R-C & F 1.8L Carb. F 3.9L 6-Cyl. Carb. 1971 Except 8R-C A/T & 8R-C & F M/T 1.8L Carb. 8R-C A/T 1.8L Carb. 8R-C & F M/T 1.8L Carb. F 3.9L 6-Cyl. Carb. 1972 F 3.9L 6-Cyl. Carb. 2T-C 1.6L Carb. 3K-C 1.2L & 18R-C 2.0L Carb. 4M 6-Cyl. 2.6L Carb. 8R-C A/T 1.8L Carb. 8R-C M/T 1.8L Carb. 1973 F 3.9L & 4M 2.6L Carb. 2T-C 1.6L Carb. 3K-C 1.2L & 18R-C 2.0L Carb. 1974
(1) Emission Control Systems & Devices

PCV, AIS PCV, (2) (3) (4) EVAP, AIS PCV, (3) (4) EVAP, SPK, (2) AIS, SPK-SC, TP PCV, (4) EVAP, SPK, (4) EVAP-VC, SPK-VR, TP PCV, (3) EVAP, AIS PCV, (3) EVAP, SPK, AIS, SPK-SC, TP PCV, (3) EVAP, SPK-TCS, TP PCV, EVAP, SPK, EVAP-VC, SPK-VR, TP PCV, EVAP, SPK, EVAP-VC, SPK-VR, TP PCV, EVAP, SPK, AIS, EVAP-VC, SPK-SC, TP PCV, EVAP, SPK, (5) AIS, EVAP-VC, SPK-SC, TP PCV, EVAP, SPK, AIS, EVAP-VC, SPK-SC, TP PCV, EVAP, SPK, AIS, EVAP-VC, SPK-SC, TP PCV, EVAP, EVAP-VC, SPK-TCS, TP PCV, EVAP, SPK, AIS, EVAP-VC, SPK-SC, TP PCV, EVAP, SPK, (5) AIS, EVAP-VC, SPK-SC, TP PCV, EVAP, SPK, (5) AIS, EVAP-VC, SPK-SC, TP

1968-2003 ENGINE PERFORMANCE Emission Applications - Toyota (1968-2003)

EVAP-VPSVSV, SPK-CC Tundra 3.4L V6 SFI PCV, EVAP, TWC, (83) WU-TWC, FR, SPK, (83) AFS, (95) HO2S, CEC, MIL, (26) EVAP-VSV, EVAP-VC, EVAP-VPS, (26) EVAP-VPSVSV, SPK-CC PCV, EVAP, (101) TWC, FR, SPK, (101) HO2S, CEC, MIL, EVAP-VC, EVAP-VPS, (26) EVAP-VPSVSV, EVAP-VSV, SPK-CC PCV, EVAP, TWC, (83) WU-TWC, FR, EGR, SPK, (83) AFS, (95) HO2S, CEC, MIL, EVAP-VC, EVAP-VPS, (26) EVAP-VPSVSV, (26) EVAP-VSV, (45) EGR-CKV, EGR-T, EGR-VM, (26) EGR-VSV, SPK-CC 4Runner 3.4L V6 SFI PCV, EVAP, TWC, (83) WU-TWC, FR, SPK, (83) AFS, (95) HO2S, CEC, MIL, EVAP-VC, EVAP-VPS, (26) EVAP-VPSVSV, (26) EVAP-VSV, SPK-CC PCV, EVAP, TWC, (98) WU-TWC, FR, SPK, (98) AFS, (98) HO2S, CEC, MIL, (26) EVAP-CCVVSV, (26) EVAP-PSVVSV, EVAP-VC, EVAP-VPS, EVAP-VST, (26) EVAP-VSV, ORVR-COV, ORVR-OCKV, SPK-CC PCV, (98) TWC, EGR, SPK, AFS, HO2S, CEC, MIL, (26) EGR-VSV, SPK-CC EGR-VM, PCV, EVAP, (98) TWC, FR, EGR, SPK, AFS, HO2S, CEC, MIL, (26) EVAP-CCVVSV, (26) EVAP-PSVVSV, EVAP-VC, EVAP-VPS, (26) EVAP-VSV, ORVR-COV, ORVR-OCKV, EGR-VM, (26) EGR-VSV, SPK-CC PCV, EVAP, TWC, (98) (20) WU-TWC, FR, EGR,, SPK, (98) (20) AFS, (101) HO2S, CEC, MIL, (26) EVAP-CCVVSV, (26) EVAP-PSVVSV, EVAP-VC, EVAP-VPS, (26) EVAP-VSV, ORVR-COV, ORVR-OCKV, EGR-PS, EGRT, EGR-VCV, (26) EGR-VSV, SPK-CC PCV, EVAP, (98) TWC, FR, EGR, SPK,

Tundra 4.7L V8 SFI

4Runner 2.7L 4-Cyl. SFI

2001 Avalon 3.0L V6 SFI

Camry 2.2L 4-Cyl. SFI (CNG)

Camry 2.2L 4-Cyl. SFI

Camry 3.0L V6 SFI

Camry Solara 2.2L 4-Cyl. SFI

1968-2003 ENGINE PERFORMANCE Emission Applications - Toyota (1968-2003)

AFS, HO2S, CEC, MIL,

(26) EVAP-CCVVSV, (26) EVAP-PSVVSV, EVAP-VPS, (26) EVAP-VSV, EVAP-VC,

ORVR-COV, ORVR-OCKV, EGR-VM, (26) EGR-VSV, SPK-CC Camry Solara 3.0L V6 SFI PCV, EVAP, TWC, (98) (20) WU-TWC, FR, EGR, SPK, (98) (20) AFS, (99) HO2S, CEC, MIL, (26) EVAP-CCVVSV, (26) EVAP-PSVVSV, EVAP-VPS, (26) EVAP-VSV, EVAP-VC, ORVR-COV, ORVR-OCKV, EGR-PS, EGRT, EGR-VSV, (26) EGR-VSV, SPK-CC PCV, EVAP, TWC, FR, SPK, (98) HO2S, CEC, MIL, (26) EVAP-CCVVSV, (26) EVAP-PSVVSV, EVAP-VC, EVAP-VSV, EVAP-VPS, ORVRCOV, ORVR-OCKV, SPK-CC PCV, EVAP, TWC, FR, SPK, (98) HO2S, CEC, MIL, (26) EVAP-CCVVSV, (26) EVAP-PSVVSV, EVAP-VC, EVAP-VSV, EVAP-VPS, ORVRCOV, ORVR-OCKV, SPK-CC PCV, EVAP, TWC, FR, SPK, (98) HO2S, CEC, MIL, (26) EVAP-CCVVSV, EVAP-VPS, EVAPVSV, EVAP-VC, ORVR-COV, ORVROCKV, SPK-CC PCV, EVAP, (98) WU-TWC, FR, SPK, (98) AFS, (98) HO2S, CEC, MIL, (26) EVAP-CCVVSV, EVAP-VC, EVAPVPS, (26) EVAP-VSV, (26) EVAP-PSVVSV, ORVR-COV, ORVR-OCKV, SPK-CC PCV, EVAP, TWC, (98) WU-TWC, FR, SPK, (98) AFS, HO2S, CEC, MIL, (26) EVAP-CCVVSV, (26) EVAP-PSVVSV, EVAP-VC, EVAP-VPS, (26) EVAP-VSV, ORVR-COV, ORVR-OCKV, SPK-CC PCV, EVAP, (98) TWC, FR, SPK, (100) HO2S, CEC, MIL, (26) EVAP-VSV, EVAP-VC, EVAP-VPS, (26) EVAP-VPSVSV, SPK-CC PCV, EVAP, TWC, (98) WU-TWC, FR, SPK, (100) HO2S, CEC, MIL,

Celica 1.8L 4-Cyl. SFI

Corolla 1.8L 4-Cyl. SFI

Echo 1.5L 4-Cyl. SFI

Highlander 2.4L 4-Cyl. SFI

Highlander 3.0L V6 SFI

Land Cruiser 4.7L V8 SFI

MR2 1.8L 4-Cyl. SFI

1968-2003 ENGINE PERFORMANCE Emission Applications - Toyota (1968-2003)

(26) EVAP-CCVVSV, (26) EVAP-PSVVSV, EVAP-VC, (26) EVAP-VSV, ORVR-COV,

ORVR-OCKV, SPK-CC Prius 1.5L Cyl. SFI PCV, EVAP, (98) TWC, FR, SPK, (98) HO2S, CEC, MIL, (26) EVAP-CCVVSV, (26) EVAP-PFSVVSV, EVAP-VC, EVAP-VPS, (26) EVAP-VSV, HCAC-VSV, SPK-CC PCV, EVAP, (98) TWC, FR, SPK, (98) AFS, (98) HO2S, CEC, MIL, (26) EVAP-CCVVSV, (26) EVAP-PSVVSV, EVAP-VPS, EVAP-VC, EVAP-VST, EVAPVSV, ORVR-COV, ORVR-OCKV, SPK-CC PCV, EVAP, (98) TWC, FR, SPK, (101) HO2S, CEC, MIL, (26) EVAP-CCVVSV, (26) EVAP-PSVVSV, EVAP-VPS, EVAP-VC, (26) EVAP-VSV, SPK-CC PCV, EVAP, TWC, (98) WU-TWC, FR, SPK, (98) AFS, HO2S, CEC, MIL, (26) EVAP-CCVVSV, (26) EVAP-PSVVSV, EVAP-VC, EVAP-VPS, EVAP-VST, (26) EVAP-SV, ORVR-COV, ORVR-OCKV, SPK-CC PCV, EVAP, (98) TWC, FR, SPK, AFS, HO2S, CEC, MIL, (26) EVAP-VPSVSV, EVAP-VC, EVAP-VPS, (26) EVAP-VSV, SPK-CC PCV, EVAP, (98) TWC, FR, EGR, SPK, AFS, HO2S, CEC, MIL, EVAP-VPS, (26) EVAP-VPSVSV, (26) EVAPVSV, EVAP-VC, EGR-T, EGR-VM, (26) EGR-VSV, SPK-CC PCV, EVAP, (98) TWC, FR, SPK, AFS, HO2S, CEC, MIL, EVAP-VC, EVAP-VPS, EVAP-VPSVSV, (26) EVAP-VSV, SPK-CC PCV, EVAP, (98) TWC, FR, SPK, AFS, HO2S, CEC, MIL, (26) EVAP-VSV, EVAP-VC, EVAP-VPS, EVAP-VPSVSV, SPK-CC PCV, EVAP, (102) TWC, FR, SPK, (101) HO2S, CEC, MIL, EVAP-VC, EVAP-VPS, (26) EVAP-VSV, (26)

RAV4 2.0L 4-Cyl. SFI

Sequoia 4.7L V8 SFI

Sienna 3.0L V6 SFI

Tacoma 2.4L 4-Cyl. SFI

Tacoma 2.7L 4-Cyl. SFI

Tacoma 3.4L V6 SFI

Tundra 3.4L V6 SFI

Tundra 4.7L V8 SFI

1968-2003 ENGINE PERFORMANCE Emission Applications - Toyota (1968-2003)

EVAP-VPSVSV, SPK-CC 4Runner 2.7L 4-Cyl. SFI PCV, EVAP, (98) TWC, FR, SPK, AFS, HO2S, CEC, MIL, (26) EVAP-CCVVSV, (26) EVAP-PSVVSV, EVAP-VC, (26) EVAP-VSV, ORVR-COV, ORVR-OCKV, SPK-CC PCV, EVAP-TWC, (20) WU-TWC, FR, SPK, (20) AFS, (20) HO2S, CEC, MIL, (26) EVAP-CCVVSV, (26) EVAP-PSVVSV, EVAP-VC, EVAP-VPS, EVAP-VST, (26) EVAP-SV, ORVR-COV, ORVR-OCKV, SPK-CC PCV, EVAP, (20) TWC, FR, SPK, AFS, HO2S, CEC, MIL, (26) EVAP-CCVVSV, (26) EVAP-PSVVSV, EVAP-VC, EVAP-VPS, (26) EVAP-VSV, ORVR-COV, ORVR-OCKV, SPK-CC PCV, EVAP, (100) TWC, FR, EGR, SPK, (20) AFS, (20) HO2S, CEC, MIL, (26) EVAP-CCVVSV, (26) EVAP-PSVVSV, EVAP-VC, EVAP-VPS, (26) EVAP-VSV, ORVR-COV, ORVR-OCKV, EGR-PS, EGRT, EGR-VCV, (26) EGR-VSV, SPK-CC PCV, EVAP, (20) TWC, FR, SPK, AFS, HO2S, CEC, MIL, (26) EVAP-CCVVSV, (26) EVAP-PSVVSV, EVAP-VPS, (26) EVAP-VSV, EVAP-VC, ORVR-COV, ORVR-OCKV, SPK-CC, PCV, EVAP, TWC, (20) (45) WU-TWC, FR, EGR, SPK, (20) (45) AFS, (103) HO2S, CEC, MIL, (26) EVAP-CCVVSV, (26) EVAP-PSVVSV, EVAP-VPS, (26) EVAP-VSV, EVAP-VC, ORVR-COV, ORVR-OCKV, EGR-PS, EGRT, EGR-VCV, (26) EGR-VSV, SPK-CC PCV, EVAP, TWC, FR, SPK, (20) HO2S, CEC, MIL, (26) EVAP-CCVVSV, (26) EVAP-PSVVSV, EVAP-VC, EVAP-VSV, EVAP-VPS, ORVRCOV, ORVR-OCKV, SPK-CC PCV, EVAP, TWC, FR, SPK, (20) HO2S, CEC, MIL, (26) EVAP-CCVVSV, (26) EVAP-PSVVSV,

2002 Avalon 3.0L V6 SFI

Camry 2.2L 4-Cyl. SFI

Camry 3.0L V6 SFI

Camry Solara 2.4L 4-Cyl. SFI

Camry 3.0L V6 SFI

Celica 1.8L 4-Cyl. SFI

Corolla 1.8L 4-Cyl. SFI

1968-2003 ENGINE PERFORMANCE Emission Applications - Toyota (1968-2003)

EVAP-VC, EVAP-VSV, EVAP-VPS, ORVRCOV, ORVR-OCKV, SPK-CC Echo 1.5L 4-Cyl. SFI PCV, EVAP, TWC, FR, SPK, (20) HO2S, CEC, MIL, (26) EVAP-CCVVSV, EVAP-VPS, EVAPVSV, EVAP-VC, ORVR-COV, ORVROCKV, SPK-CC PCV, EVAP, (20) TWC, FR, SPK, (20) AFS, (20) HO2S, CEC, MIL, (26) EVAP-CCVVSV, EVAP-VC, EVAPVPS, (26) EVAP-VSV, (26) EVAP-PSVVSV, ORVR-COV, ORVR-OCKV, SPK-CC PCV, EVAP, TWC, (20) WU-TWC, FR, SPK, (20) AFS, HO2S, CEC, MIL, (26) EVAP-CCVVSV, (26) EVAP-PSVVSV, EVAP-VC, EVAP-VPS, (26) EVAP-VSV, ORVR-COV, ORVR-OCKV, SPK-CC PCV, EVAP, (20) TWC, FR, SPK, (101) HO2S, CEC, MIL, (26) EVAP-VSV, EVAP-VC, EVAP-VPS, (26) EVAP-VPSVSV, SPK-CC PCV, EVAP, TWC, (100) WU-TWC, FR, SPK, (100) HO2S, CEC, MIL, (26) EVAP-CCVVSV, (26) EVAP-PSVVSV, EVAP-VC, (26) EVAP-VSV, ORVR-COV, ORVR-OCKV, SPK-CC PCV, EVAP, (20) TWC, FR, SPK, (20) HO2S, CEC, MIL, (26) EVAP-CCVVSV, (26) EVAP-PFSVVSV, EVAP-VC, EVAP-VPS, (26) EVAP-VSV, (26) HCAC-VSV, SPK-CC PCV, EVAP, (20) TWC, FR, SPK, (20) AFS, (20) HO2S, CEC, MIL, (26) EVAP-CCVVSV, (26) EVAP-PSVVSV, EVAP-VPS, EVAP-VC, EVAP-VST, EVAPVSV, ORVR-COV, ORVR-OCKV, SPK-CC PCV, EVAP, (20) TWC, FR, SPK, (103) HO2S, CEC, MIL, (26) EVAP-CCVVSV, (26) EVAP-PSVVSV, EVAP-VPS, EVAP-VC, (26) EVAP-SV, SPKCC PCV, EVAP, TWC, (20) WU-TWC, FR, SPK, (20) AFS, HO2S, CEC, MIL, (26) EVAP-CCVVSV, (26) EVAP-PSVVSV,

Highlander 2.4L 4-Cyl. SFI

Highlander 3.0L V6 SFI

Land Cruiser 4.7L V8 SFI

MR2 1.8L 4-Cyl. SFI

Prius 1.5L 4-Cyl. SFI

RAV4 2.0L 4-Cyl. SFI

Sequoia 4.7L V8 SFI

Sienna 3.0L V6 SFI

1968-2003 ENGINE PERFORMANCE Emission Applications - Toyota (1968-2003)

EVAP-VC, EVAP-VPS, EVAP-VST, (26) EVAP-VSV, ORVR-COV, ORVR-OCKV, SPK-CC Tacoma 2.4L 4-Cyl. SFI PCV, EVAP, (20) TWC, FR, SPK, AFS, HO2S, CEC, MIL, (26) EVAP-VPSVSV, EVAP-VC, EVAP-VPS, (26) EVAP-VSV, SPK-CC PCV, EVAP, (20) TWC, FR, EGR, SPK, AFS, HO2S, CEC, MIL, (26) EVAP-CCVVSV, (26) EVAP-PSVVSV, EVAP-VPS, (26) EVAP-VSV, EVAP-VC, ORVR-OCKV, EGR-T, EGR-VM, (26) EGRVSV, SPK-CC PCV, EVAP, (20) TWC, FR, SPK, AFS, HO2S, CEC, MIL, (26) EVAP-CCVVSV, (26) EVAP-PSVVSV, EVAP-VC, EVAP-VPS, (26) EVAP-VSV, ORVR-COV, ORVR-OCKV, SPK-CC PCV, EVAP, (20) TWC, FR, SPK, AFS, HO2S, CEC, MIL, (26) EVAP-VSV, EVAP-VC, EVAP-VPS, EVAP-VPSVSV, SPK-CC PCV, EVAP, (104) TWC, FR, SPK, (101) HO2S, CEC, MIL, EVAP-VC, EVAP-VPS, (26) EVAP-VSV, (26) EVAP-VPSVSV, SPK-CC PCV, EVAP, (20) TWC, FR, SPK, AFS, HO2S, CEC, MIL, (26) EVAP-CCVVSV, (26) EVAP-PSVVSV, EVAP-VC, (26) EVAP-VSV, ORVR-COV, ORVR-OCKV, SPK-CC PCV, EVAP, TWC, WU-TWC, FR, SPK, (106) AFS, HO2S, CEC, MIL (107) EVAP-VSV, EVAP-VC, EVAP-VST, EVAP-VPS, (107) EVAP-CCVVSV, (107) EVAP-PSVVSV, ORVR-COV, ORVROCKV, SPK-CC PCV, EVAP, (108) TWC, FR, SPK, AFS, HO2S, CEC, MIL (107) EVAP-VSV, EVAP-VC, EVAP-VPS, (107) EVAP-CCVVSV, (107) EVAP-PSVVSV, ORVR-COV, ORVR-OCKV, SPK-CC PCV, EVAP, (100) TWC, FR, SPK, AFS,

Tacoma 2.7L 4-Cyl. SFI

Tacoma 3.4L V6 SFI

Tundra 3.4L V6 SFI

Tundra 4.7L V8 SFI

4Runner 2.7L 4-Cyl. SFI

2003 Avalon 3.0L V6 SFI

Camry 2.4L 4-Cyl. SFI Except PZEV

Camry 2.4L 4-Cyl. SFI PZEV

1968-2003 ENGINE PERFORMANCE Emission Applications - Toyota (1968-2003)

(100) HO2S, CEC, MIL

EVAP-TC, (107) EVAP-VSV, EVAP-VC, EVAP-VPS, (107) EVAP-CCVVSV, (107) EVAP-PSVVSV, ORVR-COV, ORVROCKV, SPK-CC Camry 3.0L V6 SFI PCV, EVAP, (107) TWC, FR, (108) EGR, SPK, (105) AFS, (100) HO2S, CEC, MIL (26) EVAP-VSV, EVAP-VC, EVAP-VPS, (26) EVAP-CCVVSV, (26) EVAP-PSVVSV, ORVR-COV, ORVR-OCKV, (108) EGR-T, (108) EGR-VCV, (108) EGR-PS, (26) (108) EGR-VSV, SPK-CC PCV, EVAP, (106) TWC, FR, SPK, AFS, HO2S, CEC, MIL (26) EVAP-VSV, EVAP-VC, EVAP-VPS, (26) EVAP-CCVVSV, (26) EVAP-PSVVSV, ORVR-COV, ORVR-OCKV, SPK-CC PCV, EVAP, TWC, WU-TWC, FR, EGR, SPK, (109) AFS, HO2S, CEC, MIL (26) EVAP-VSV, EVAP-VC, EVAP-VPS, (26) EVAP-CCVVSV, (26) EVAP-PSVVSV, ORVR-COV, ORVR-OCKV, EGR-T, EGRVCV, EGR-PS, (26) EGR-VSV, SPK-CC PCV, EVAP, TWC, FR, SPK, (100) HO2S, CEC, MIL (26) EVAP-VSV, EVAP-VC, EVAP-VPS, (26) EVAP-CCVVSV, (26) EVAP-PSVVSV, ORVR-COV, ORVR-OCKV, SPK-CC PCV, EVAP, TWC, FR, SPK, (100) HO2S, CEC, MIL (26) EVAP-VSV, EVAP-VC, EVAP-VPS, (26) EVAP-CCVVSV, (26) EVAP-PSVVSV, ORVR-COV, ORVR-OCKV, SPK-CC PCV, EVAP, TWC, FR, SPK, (26) HO2S, CEC, MIL (26) EVAP-VSV, EVAP-VC, EVAP-VPS, (26) EVAP-CCVVSV, ORVR-COV, ORVROCKV, SPK-CC PCV, EVAP, (100) TWC, FR, SPK, (100) AFS, (100) HO2S, CEC, MIL (26) EVAP-VSV, EVAP-VC, EVAP-VPS, (26) EVAP-CCVVSV, (26) EVAP-PSVVSV, ORVR-COV, ORVR-OCKV PCV, EVAP, TWC, WU-TWC, FR, SPK,

Camry Solara 2.4L 4-Cyl. SFI

Camry 3.0L V6 SFI

Celica 1.8L 4-Cyl. (1ZZ-FE & 2ZZ-GE) SFI

Corolla 1.8L 4-Cyl. SFI

Echo 1.5L 4-Cyl. SFI

Highlander 2.4L 4-Cyl. SFI

Highlander 3.0L V6 SFI

1968-2003 ENGINE PERFORMANCE Emission Applications - Toyota (1968-2003)

(105) AFS, HO2S, CEC, MIL (26) EVAP-VSV, EVAP-VC, EVAP-VPS, (26) EVAP-CCVVSV, (26) EVAP-PSVVSV,

ORVR-COV, ORVR-OCKV, SPK-CC Land Cruiser 4.7L V8 SFI PCV, EVAP, (100) TWC, FR, SPK, (101) HO2S, CEC, MIL (26) EVAP-VSV, EVAP-VC, EVAP-VPS, (26) EVAP-CCVVSV, SPK-CC PCV, EVAP, TWC, FR, SPK, (100) HO2S, CEC, MIL (26) EVAP-VSV, EVAP-VC, EVAP-VPS, (26) EVAP-CCVVSV, (26) EVAP-PSVVSV, ORVR-COV, ORVR-OCKV PCV, EVAP, (100) TWC, FR, SPK, (100) HO2S, CEC, MIL (26) EVAP-VSV, EVAP-VC, EVAP-VPS, (26) EVAP-CCVVSV, (26) EVAP-PSVVSV, ORVR-COV, ORVR-OCKV, SPK-CC PCV, EVAP, (20) TWC, FR, SPK, (100) HO2S, CEC, MIL (26) EVAP-VSV, EVAP-VC, EVAP-VPS, (26) EVAP-CCVVSV, (26) EVAP-PFSVVSV, (26) HCAC-VSV, SPK-CC PCV, EVAP, (100) TWC, FR, SPK, (100) AFS, (100) HO2S, CEC, MIL (26) EVAP-VSV, EVAP-VC, EVAP-VST, EVAP-VPS, (26) EVAP-CCVVSV, (26) EVAP-PSVVSV, ORVR-COV, ORVROCKV, SPK-CC PCV, EVAP, (100) TWC, FR, SPK, (101) HO2S, CEC, MIL (26) EVAP-VSV, EVAP-VC, EVAP-VPS, (26) EVAP-CCVVSV, (26) EVAP-PSVVSV, ORVR-COV, ORVR-OCKV, SPK-CC PCV, EVAP, TWC, (100) WU-TWC, FR, SPK, (105) AFS, HO2S, CEC, MIL (26) EVAP-VSV, EVAP-VC, EVAP-VST, EVAP-VPS, (26) EVAP-CCVVSV, (26) EVAP-PSVVSV, ORVR-COV, ORVROCKV, SPK-CC PCV, EVAP, (100) TWC, FR, SPK, AFS, HO2S, CEC, MIL (26) EVAP-VSV, EVAP-VC, EVAP-VPS, (26) EVAP-CCVVSV, (26) EVAP-PSVVSV,

Matrix 1.8L 4-Cyl. SFI

MR2 1.8L 4-Cyl. SFI

Prius 1.5L 4-Cyl. SFI

RAV4 2.0L 4-Cyl. SFI

Sequoia 4.7L V8 SFI

Sienna 3.0L V6 SFI

Tacoma 2.4L 4-Cyl. SFI

1968-2003 ENGINE PERFORMANCE Emission Applications - Toyota (1968-2003)

ORVR-COV, ORVR-OCKV, SPK-CC Tacoma 2.7L 4-Cyl. SFI PCV, EVAP, (100) TWC, FR, EGR, SPK, AFS, HO2S, CEC, MIL (26) EVAP-VSV, EVAP-VC, EVAP-VPS, (26) EVAP-CCVVSV, (26) EVAP-PSVVSV, ORVR-COV, ORVR-OCKV, EGR-T, EGRVM, (26) EGR-VSV, SPK-CC PCV, EVAP, (100) TWC, FR, SPK, AFS, HO2S, CEC, MIL (26) EVAP-VSV, EVAP-VC, EVAP-VPS, (26) EVAP-CCVVSV, (26) EVAP-PSVVSV, ORVR-COV, ORVR-OCKV, SPK-CC PCV, EVAP, (100) TWC, FR, SPK, AFS, HO2S, CEC, MIL (26) EVAP-VSV, EVAP-VC, EVAP-VPS, (26) EVAP-CCVVSV, SPK-CC PCV, EVAP, TWC, FR, SPK, (101) HO2S, CEC, MIL (26) EVAP-VSV, EVAP-VC, EVAP-VPS, (26) EVAP-CCVVSV, SPK-CC PCV, EVAP, (101) TWC, FR, SPK, (105) AFS, (101) HO2S, CEC, MIL (26) EVAP-VSV, EVAP-VC, EVAP-VPS, (26) EVAP-CCVVSV, (26) EVAP-PSVVSV, ORVR-COV, ORVR-OCKV, SPK-CC

Tacoma 3.4L V6 SFI

Tundra 3.4L V6 SFI

Tundra 4.7L V8 SFI

4Runner 4.0L V6 SFI

PCV, EVAP, TWC, FR, SPK, (101) HO2S, CEC, MIL (26) EVAP-VSV, EVAP-VC, EVAP-VPS, (26) EVAP-CCVVSV, SPK-CC (1) Major emission control systems and devices are listed in bold type; components and other related devices are listed in light type. (2) Except 8R-C & 18R-C. 4Runner 4.7L V8 SFI
(3) Uses fuel storage case type system. (4) California only. (5) Some models. (6) Federal only. (7) Except Hi-Lux models. (8) Cold weather application only. (9) Except Federal Pickup. (10) High Altitude only. (11) Federal M/T only.

1968-2003 ENGINE PERFORMANCE Emission Applications - Toyota (1968-2003)

(12) Federal (Cab & Chassis) & Calif. (All models). (13) Except California 2WD. (14) Check emission label. (15) California 4WD only. (16) Except 103 HP engines. (17) Vapor canister type. (18) Spark Control Timing System (SPK-TCSYS). (19) Calif. 2WD & all 4WD only. (20) Equipped with 2. (21) Equipped with 2 on Calif. models. (22) Spark Timing Control System (SPK-TCSYS). (23) Except California A/T. (24) Federal & Canada only. (25) California & Turbo models only. (26) ECM/ECU controlled. (27) In-line vacuum check valve. (28) Exhaust check valve. (29) A/T & Calif. models only. (30) Federal A/T & all Calif. models. (31) Calif. & all cab/chassis models. (32) Calif. 2WD models only. (33) One on exhaust manifold & one on exhaust pipe. (34) Equipped with 2. One on each bank. (35) One on exhaust pipe on all except Calif. models. One on exhaust manifold & one on exhaust

pipe on Calif. models. (36) One on exhaust pipe & exhaust manifold on Calif. models. All others use only one on exhaust manifold. (37) Two sensors are used on all models. On Calif. models, HO2S are used.
(38) One on each bank.& one on exhaust pipe, behind catalytic converter. (39) Except Calif. emissions. (40) Heated sensor. (41) One on exhaust pipe in front of catalytic converter & one on exhaust pipe behind catalytic

converter. (42) One on exhaust pipe & manifold on Calif. models. All others use only one on exhaust manifold.

1968-2003 ENGINE PERFORMANCE Emission Applications - Toyota (1968-2003)

(43) Used on all Calif. models & only on A/T except Calif. models. (44) Equipped with 2 on all models. On Calif. models, HO2S are used. (45) A/T only. (46) Applies to all 2WD & 4WD regular cab models. (47) One on each bank & one on exhaust pipe, behind catalytic converter. (48) One on each manifold & one on exhaust pipe. (49) One on exhaust pipe in front of catalytic converter & one on exhaust pipe behind catalytic

converter. (50) All 2WD & 4WD regular cab models.

(51) 2WD 1/2 ton models & Regular Cab. (52) M/T only. (53) Non-heated sensor is used on exhaust manifold before catalytic converter. Heated sensor is used

behind catalytic converter. (54) One on exhaust pipe in front of front catalytic converter & one on exhaust pipe behind rear catalytic converter. (55) Equipped with 3. One on each exhaust manifold in front of front catalytic converter & one on exhaust pipe behind front catalytic converter. (56) One on each bank & one on exhaust pipe, behind catalytic converter.
(57) On Calif. emissions, one on exhaust manifold & one on exhaust pipe. On except Calif.

emissions, one on exhaust pipe. (58) Calif. emissions only. HO2S mounted on exhaust manifold above catalytic converter.
(59) On Calif. emissions, one on exhaust pipe behind catalytic converter. On except Calif. emissions,

one on exhaust manifold & one on exhaust pipe behind catalytic converter. (60) Non-heated sensor is used on exhaust pipe before catalytic converter. Heated sensor is used on exhaust pipe behind catalytic converter. (61) One on exhaust manifold & one on exhaust pipe.
(62) One on exhaust manifold before front catalytic converter & one on bottom of front catalytic

converter. (63) One on exhaust pipe in front of catalytic converter & one on exhaust pipe behind rear catalytic converter. (64) Non-heated sensor is used on exhaust manifold. Hated sensor is used on exhaust pipe behind catalytic converter. (65) One on exhaust pipe in front of front catalytic converter & one on exhaust pipe behind front catalytic converter. (66) Equipped with 3. One on each exhaust manifold ahead of front catalytic converter & one on exhaust pipe behind front catalytic front catalytic converter. (67) One on exhaust gas control valve assembly on rear of turbocharger & one on exhaust pipe in front of rear catalytic converter. (68) Applies to all 2WD models & 4WD regular cab models.

1968-2003 ENGINE PERFORMANCE Emission Applications - Toyota (1968-2003)

(69) Applies to 2WD 1/2 ton models & Regular Cab. (70) One on exhaust pipe on all models. (71) Calif. emission vehicles only. One on each bank below exhaust manifold. (72) Calif. emission vehicles only. One heated sensor on each exhaust manifold. (73) On Calif. emission vehicles, one on exhaust pipe behind catalytic converter. On all other

vehicles, one on each exhaust manifold & one on exhaust pipe behind catalytic converter. (74) On Calif. emission vehicles, one on exhaust manifold & one on exhaust pipe. On all other vehicles, one on exhaust pipe. (75) Calif. emission vehicles only. HO2S on exhaust manifold above catalytic converter.
(76) On Calif. emission vehicles, one on exhaust pipe behind catalytic converter. On all other

vehicles, one near exhaust manifold & one on exhaust pipe behind catalytic converter. (77) Calif. emission vehicles with A/T only. One on each bank below exhaust manifold.
(78) Calif. emission vehicles with A/T only. HO2S on each exhaust manifold. (79) On Calif. emission vehicles with A/T, one on exhaust pipe behind catalytic converter. On all

other vehicles with A/T, one on each exhaust manifold & one on exhaust pipe behind catalytic converter. (80) One on exhaust & one on exhaust pipe.
(81) One on exhaust manifold before front catalytic converter & one on bottom of front catalytic

converter. (82) Except Calif. emission vehicles only.

(83) Calif. emission vehicles only. (84) One on exhaust pipe before catalytic converter & one on exhaust pipe behind catalytic converter. (85) Equipped with 4. One on each exhaust manifold & one on each exhaust pipe behind catalytic

converter. (86) One on each exhaust manifold & one on exhaust pipe behind catalytic converter.
(87) One on exhaust gas control valve assembly on rear of turbocharger & one on exhaust pipe in

front of rear catalytic converter. (88) All 2WD & 4WD regular cab models.
(89) Non-heated sensor is used on exhaust manifold. Heated sensor is used on exhaust pipe behind

catalytic converter. (90) 2WD 1/2 ton models & Regular Cab.
(91) Calif. emission vehicles with A/T only. (92) On Calif. emission vehicles, one on exhaust manifold & one on exhaust pipe. On all other

models, one on exhaust pipe. (93) On Calif. emission vehicles, one behind catalytic converter. On all other models, one near exhaust manifold & one behind catalytic converter. (94) On Calif. emission vehicles, one behind catalytic converter. On all other models, one on each exhaust manifold & one behind catalytic converter. (95) On Calif. emission vehicles, one behind catalytic converter. On all other models, one in front &

1968-2003 ENGINE PERFORMANCE Emission Applications - Toyota (1968-2003)

one behind catalytic converter. (96) 2WD & 4WD Calif. vehicles.
(97) On Calif. emission vehicles, one on each exhaust pipe near exhaust manifold & one on rear

exhaust pipe. On all other models, one on each pipe near exhaust manifold. (98) One on each exhaust manifold.
(99) On A/T models, one behind catalytic converter. On M/T models, one near exhaust manifold &

one behind catalytic converter. (100) Equipped with 3.

(101) Equipped with 4. (102) On Calif. emission vehicles, one on each exhaust pipe near manifold & one on rear exhaust

pipe. On except Calif. emission vehicles, one on each exhaust pipe near manifold. (103) On A/T models, one on exhaust pipe behind catalytic converter. On M/T models, one on each exhaust manifold & one on exhaust pipe behind catalytic converter. (104) On Calif. emission vehicles, one on each exhaust manifold & one on rear exhaust pipe. On Federal emission vehicles, one on each exhaust pipe near exhaust manifold. (105) One on each exhaust manifold.
(106) One on exhaust manifold and one on exhaust pipe. (107) One on each bank below exhaust manifold and one on exhaust pipe. (108) Only on vehicles built before Jan. 2003. (109) Heated sensor on each exhaust manifold.

ABBREVIATIONS
ACL Air Cleaner (Thermostatic Air Cleaner) ADS Anti-Dieseling Solenoid AFS Air/Fuel Ratio Sensor AIS Air Injection System AP Air Pump Injection System

1968-2003 ENGINE PERFORMANCE Emission Applications - Toyota (1968-2003)

AP-ASV AP Air Switching Valve AP-BPV AP By-Pass Valve AP-CKV AP Check Valve AP-RDV AP Reed Valve AP-TV AP Transmitting Valve AP-VSV AP Vacuum Switching Valve A/T Automatic Transmission CEC Computerized Engine Control CMH Cold Mixture Heater DCS Deceleration Control System DOHC Dual Overhead Cam ECU Electronic Control Unit EFE

1968-2003 ENGINE PERFORMANCE Emission Applications - Toyota (1968-2003)

Early Fuel Evaporation EFE-HCV EFE Heat Control Valve EFI Electronic Fuel Injection EGR Exhaust Gas Recirculation EGR-BVSV EGR Bimetallic Vacuum Switching Valve EGR-CKV EGR Check Valve EGR-CLR EGR Cooler EGR-PS EGR EGREGR Position Sensor EGR-T EGR Temperature Sensor EGR-TVV EGR Thermal Vacuum Valve EGR-VCV EGR Vacuum Control/Check Valve EGR-VM EGR Vacuum Modulator

1968-2003 ENGINE PERFORMANCE Emission Applications - Toyota (1968-2003)

EGR-VSV EGR Vacuum Switching Valve EVAP Fuel Evaporative System EVAP-BVSV EVAP Bimetallic Vacuum Switching Valve EVAP-CCVVSV EVAP Canister Closed Valve Vacuum Switching Valve EVAP-CKV EVAP Check Valve EVAP-OVCV EVAP Outer Vent Control Valve EVAP-PFSVVSV EVAP Purge Flow Switching Valve Vacuum Switching Valve EVAP-PSVVSV EVAP Pressure Switching Valve Vacuum Switching Valve EVAP-TV EVAP Thermal Valve EVAP-TVV EVAP Thermal Vacuum Valve EVAP-VC EVAP Vapor Canister EVAP-VCTV EVAP Vacuum Control Valve EVAP-VPS

1968-2003 ENGINE PERFORMANCE Emission Applications - Toyota (1968-2003)

EVAP Vapor Pressure Sensor EVAP-VPSVSV EVAP Vapor Pressure Sensor Vacuum Switching Valve EVAP-VST EVAP Vacuum Surge Tank EVAP-VSV EVAP Vacuum Switching Valve FBC Feedback Carburetor FR Fill Pipe Restrictor HAC High Altitude Compensator HAI Hot Air Intake HAS High Altitude System HCAC-VSV Hydrocarbon Adsorber Catalyst Vacuum Switching Valve HIC Hot Idle Compensator HP Horsepower HO2S Heated Oxygen Sensor

1968-2003 ENGINE PERFORMANCE Emission Applications - Toyota (1968-2003)

MFI Multiport Fuel Injection MIL Malfunction Indicator Light OC Oxidation Catalytic Converter ORVR On-Board Refueling Vapor Recovery ORVR-COV ORVR Cut-Off Valve ORVR-OCKV ORVR Overfill Check Valve O2S Oxygen Sensor PAIR Pulsed Secondary Air Injection PAIR-CKV PAIR Check Valve PAIR-RES PAIR Resonator PAIR-RV PAIR Reed Valve PAIR-VSV PAIR Vacuum Switching Valve PCV

1968-2003 ENGINE PERFORMANCE Emission Applications - Toyota (1968-2003)

Positive Crankcase Ventilation PVCS Power Valve Control System SFI Sequential Multiport Fuel Injection SPK Spark Controls SPK-BVSV SPK Bimetal Vacuum Switching Valve SPK-CC SPK Computer Controlled SPK-DDD SPK Dual Diaphragm Distributor SPK-DV SPK Delay Valve SPK-TCSYS SPK Timing Control System SPK-VR SPK Vacuum Retard SUB-O2S Sub-Oxygen Sensor SUB-TWC Sub Three-Way Catalytic Converter TP Throttle Position

1968-2003 ENGINE PERFORMANCE Emission Applications - Toyota (1968-2003)

TWC Three-Way Catalytic Converter TWC+OC Three-Way + Oxidation Catalytic Converter WU-TWC Warm-Up Three-Way Catalytic Converter

2002 ENGINE PERFORMANCE Pin Voltage Charts

2002 ENGINE PERFORMANCE Pin Voltage Charts

INTRODUCTION
Pin voltage charts are used for diagnosing intermittent symptoms and faults that are unable to be resolved during self-diagnostics. Pin voltage tests ensure the Engine Control Module (ECM) is receiving and transmitting proper voltage and other signals. Before performing pin voltage tests, ensure engine mechanical condition has been thoroughly inspected and self-diagnostics has been attempted. Technical Service Bulletins (TSBs) may also be helpful in correcting a hard to diagnose problem. NOTE: Unless stated otherwise, perform all voltage tests using a Digital VoltOhmmeter (DVOM) with a minimum 10-megohm input impedance. Voltage readings may vary slightly due to battery condition or charging rate. When battery is disconnected, vehicle computer and memory systems may lose memory data. Driveability problems may exist until computer systems have completed a relearn cycle.

ENGINE CONTROL MODULE LOCATION For Engine Control Module (ECM) location, see ECM LOCATION table. ECM LOCATION Model Avalon Camry & Camry Solara Celica
(1) Location

Behind Glove Box, Near Passenger's Side Kick Panel Behind Glove Box In Engine Compartment, Below Cover, Just In Front Of Battery, Next To Driver's Side Strut Tower Corolla Behind Stereo On Instrument Panel, Just In Front Of Center Console ECHO & Highlander Behind Glove Box Land Cruiser Above Glove Box, Near Passenger's Side Of Instrument Panel MR2 On Inside Of Firewall, Directly Behind Driver's Seat & Luggage Compartment Prius Behind Glove Box RAV4 Near Passenger's Side Kick Panel, Just Below Instrument Panel Sequoia Behind Glove Box & Heater Duct Sienna Passenger's Side Of Instrument Panel, Just Below Glove Box Tacoma & 4Runner Behind Glove Box Tundra Behind Glove Box & Heater Duct (1) For illustration of ECM location, see ENGINE CONTROL MODULE under COMPUTERIZED ENGINE CONTROLS in THEORY & OPERATION article.

2002 ENGINE PERFORMANCE Pin Voltage Charts

NOTE:

On Avalon, Camry, Camry Solara, Highlander, Land Cruiser, MR2, Prius, RAV4, Sequoia, Sienna and 4Runner, an engine immobilizer system may be used. Engine immobilizer system is a theft deterrent system which disables the engine from starting by not allowing ignition system operation and fuel injector operation unless proper ignition key is used. Models equipped with engine immobilizer system may be identified by looking at the ignition key. On models equipped with engine immobilizer system the top of the ignition key is thicker than a standard ignition key, as a transponder chip is incorporated into the top of the ignition key. For additional information on system operation and testing, see appropriate ENGINE IMMOBILIZER SYSTEMS article in ACCESSORIES & EQUIPMENT.

SERVICE PRECAUTIONS
PRIUS WARNING: When performing any inspection or service procedure on this vehicle, ensure following service precautions are followed to prevent personal injury or death due to the extremely high voltage. The following service precautions must be followed:

Ensure ignition is off and ignition key is removed from ignition before performing any inspection or service procedure in engine compartment, as engine may automatically start and shut off when ignition is on and READY light is illuminated. READY light is displayed just above the shift lever position indicator on instrument cluster at center of instrument panel. Read all service and warning labels in engine compartment before performing any procedures in engine compartment. All high-voltage wiring harness connectors contain Orange connectors. DO NOT touch any wiring harness that contains Orange connectors. High-voltage battery and other high-voltage components may be identified by HIGH VOLTAGE caution labels on them. DO NOT touch these components. If necessary to inspect or service high-voltage system, ensure ignition is off. Remove service plug and wait at least 5 minutes to ensure high voltage is fully discharged before touching any high-voltage wiring harness, connectors or components. Service plug is located on service plug assembly at driver's side front corner of trunk compartment, near high-voltage battery. See Fig. 1 . Ensure service plug is stored in a location in which no one may install service plug while technician is working on the vehicle. If necessary to touch any high-voltage wiring harness, connectors or components, ensure service plug is removed and battery voltage or less exists at electrical connector. Use Toyota insulated gloves when touching any high-voltage wiring harness, connectors or components. Ensure insulated gloves are dry and in good condition and that no holes exist in insulated gloves. Test by applying air pressure to insulated glove before touching any high-voltage wiring harness, connectors or components. DO NOT wear any metal objects while working on vehicle which may accidently drop and cause a short circuit. If any high-voltage wiring harness connector is disconnected, ensure terminal on wiring harness connector is wrapped with tape to prevent wiring harness connector from contacting any surface. If servicing high-voltage system, place sign on roof of vehicle to indicate to other technicians that

2002 ENGINE PERFORMANCE Pin Voltage Charts

NOTE:

Pin voltage charts are charts provided from manufacturer. Manufacturer does not provide pin voltage for all circuits at Engine Control Module (ECM). For additional terminal and wire color identification at ECM, see WIRING DIAGRAMS article.

PIN VOLTAGE CHART INDEX CAUTION: On Prius, read SERVICE PRECAUTIONS before using pin voltage chart to prevent personal injury. For appropriate pin voltage chart figure reference, see PIN VOLTAGE CHART INDEX table. PIN VOLTAGE CHART INDEX Model Avalon Camry 2.4L 4-Cyl. 3.0L V6 Camry Solara 2.4L 4-Cyl. 3.0L V6 Celica Corolla With M/T Or 3-Speed A/T With 4-Speed A/T ECHO Highlander 2.4L 4-Cyl. 3.0L V6 Land Cruiser MR2 Prius (1)

Figure Reference Fig. 2 & Fig. 3 Fig. 4 & Fig. 5 Fig. 6 -Fig. 8 Fig. 9 & Fig. 10 Fig. 11 & Fig. 12 Fig. 13 & Fig. 14 Fig. 15 & Fig. 16 Fig. 17 & Fig. 18 Fig. 19 & Fig. 20 Fig. 21 & Fig. 22 Fig. 23 & Fig. 24 Fig. 25 & Fig. 26 Fig. 27 & Fig. 28 Fig. 29 & Fig. 30

Fig. 31 & Fig. 32 RAV4 (2) Sequoia Fig. 33 & Fig. 34 Sienna Fig. 35 & Fig. 36 Tacoma 2.4L & 2.7L 4-Cyl. Fig. 37 & Fig. 38 3.4L V6 Fig. 39 & Fig. 40 Tundra 3.4L V6 Fig. 41 & Fig. 42 4.7L V8 Fig. 43 & Fig. 44 4Runner Fig. 45 & Fig. 46 (1) Before using pin voltage charts, read SERVICE PRECAUTIONS to prevent personal injury. There are 2 different wiring harnesses used in which there may be 2 different wire colors listed in

2002 ENGINE PERFORMANCE Pin Voltage Charts

(2) pin voltage chart. For example, pin voltage chart may list a R-W (SB) wire which is a Red/White

or Sky Blue wire. Some electrical connectors may have all the same colored wires. On electrical connectors with the same colored wires, the wires are numbered near each electrical connector. NOTE: When using pin voltage charts, it may be necessary to determine wire color by using wire color abbreviation. See WIRE COLOR ABBREVIATIONS table. When using pin voltage charts, the ignition switch may be referred to as IG switch.

WIRE COLOR ABBREVIATIONS (1) Wire Color Abbreviation B BR G GR L LG O P R SB V W Y

(1) Example: L-Y is a Blue wire with a Yellow tracer.

Wire Color Black Brown Green Gray Blue Light Green Orange Pink Red
(2) Sky Blue

Violet White Yellow

(2) Sky Blue wire is referred to as Light Blue wire in testing procedures and wiring diagrams.

NOTE:

For wiring circuit identification, see WIRING DIAGRAMS article.

2002 ENGINE PERFORMANCE Pin Voltage Charts

Fig. 15: Pin Voltage Chart (Corolla With M/T Or 3-Speed A/T - 1 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 ENGINE PERFORMANCE Pin Voltage Charts

Fig. 16: Pin Voltage Chart (Corolla With M/T Or 3-Speed A/T - 2 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 ENGINE PERFORMANCE Pin Voltage Charts

Fig. 17: Pin Voltage Chart (Corolla With 4-Speed A/T - 1 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 ENGINE PERFORMANCE Pin Voltage Charts

Fig. 18: Pin Voltage Chart (Corolla With 4-Speed A/T - 2 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 ENGINE PERFORMANCE Removal, Overhaul & Installation - 4-Cylinder

2002 ENGINE PERFORMANCE Removal, Overhaul & Installation - 4-Cylinder

INTRODUCTION
NOTE: Before performing removal, overhaul and installation procedures, check for any related Technical Service Bulletins (TSBs). WARNING: On Prius, read service precautions before proceeding with service procedure. See SERVICE PRECAUTIONS . CAUTION: When battery is disconnected, vehicle computer and memory systems may lose memory data. Driveability problems may exist until computer systems have completed a relearn cycle. Removal, overhaul and installation procedures are covered in this article. If component removal and installation is primarily an unbolt and bolt-on procedure, only a torque specification may be furnished.

SERVICE PRECAUTIONS
PRIUS WARNING: When performing any inspection or service procedure on this vehicle, ensure following service precautions are followed to prevent personal injury or death due to the extremely high voltage. The following service precautions must be followed:

Ensure ignition is off and ignition key is removed from ignition before performing any inspection or service procedure in engine compartment, as engine may automatically start and shut off when ignition is on and READY light is illuminated. READY light is displayed just above the shift lever position indicator on instrument cluster at center of instrument panel. Read all service and warning labels in engine compartment before performing any procedures in engine compartment. All high-voltage wiring harness connectors contain Orange connectors. DO NOT touch any wiring harness that contains Orange connectors. High-voltage battery and other high-voltage components may be identified by HIGH VOLTAGE caution labels on them. DO NOT touch these components. If necessary to inspect or service high-voltage system, ensure ignition is off. Remove service plug and wait at least 5 minutes to ensure high voltage is fully discharged before touching any high-voltage wiring harness, connectors or components. Service plug is located on service plug assembly at driver's side front corner of trunk compartment, near high-voltage battery. See Fig. 1 . Ensure service plug is stored in a location in which no one may install service plug while technician is working on the vehicle. If necessary to touch any high-voltage wiring harness, connectors or components, ensure service plug is removed and battery voltage or less exists at electrical connector. Use Toyota insulated gloves when

2002 ENGINE PERFORMANCE Removal, Overhaul & Installation - 4-Cylinder

touching any high-voltage wiring harness, connectors or components. Ensure insulated gloves are dry and in good condition and that no holes exist in insulated gloves by applying air to insulated glove before touching any high-voltage wiring harness, connectors or components. DO NOT wear any metal objects while working on vehicle which may accidently drop and cause a short circuit. If any high-voltage wiring harness connector is disconnected, ensure terminal on wiring harness connector is wrapped with tape to prevent wiring harness connector from contacting any surface. If servicing high-voltage system, place sign on roof of vehicle to indicate to other technicians that high-voltage system is being serviced.

2002 ENGINE PERFORMANCE Removal, Overhaul & Installation - 4-Cylinder

Fig. 1: Locating Service Plug & Service Plug Assembly (Prius) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

PROGRAMMING
POWER SUN ROOF REINITIALIZATION PROCEDURE

2002 ENGINE PERFORMANCE Removal, Overhaul & Installation - 4-Cylinder

Camry

NOTE:

Following procedure should be performed if battery is disconnected and reconnected, or battery is discharged and recharged to provide proper automatic operation and jam protection operation of power sun roof.

1. Ensure ignition is on. Depress and hold TILT UP side of power sun roof switch until power sun roof tilts all the way upward and then tilts downward a little. Power sun roof switch is located on headliner, just in front of power sun roof. 2. Check proper operation of open/closing and tilt up/down function for power sun roof using power sun roof switch. Power sun roof should operate anytime ignition is on, or for 43 seconds after ignition is off provided both front doors are closed. It will stop operating if any front door is opened. Depressing SLIDE OPEN side of power sun roof switch for one second should open power sun roof. Depressing TILT UP side of power sun roof switch for one second should close power sun roof. To tilt power sun roof upward, depress and hold TILT UP side of power sun roof switch for one second. To tilt power sun roof downward, depress and hold SLIDE OPEN side of power sun roof switch for one second.
Celica

NOTE:

Following procedure should be performed if battery is disconnected and reconnected, or battery is discharged and recharged to provide proper automatic operation and jam protection operation of power sun roof.

Close power sun roof using power sun roof switch and continue to depress power sun roof switch briefly after power sun roof is fully closed. Power sun roof switch is located on headliner, just in front of power sun roof.

AIR INDUCTION SYSTEMS

ACOUSTIC CONTROL INDUCTION SYSTEM VACUUM SWITCHING VALVE NOTE: Acoustic Control Induction System (ACIS) Vacuum Switching Valve (VSV) may also be referred to as intake air control valve system VSV.

Removal & Installation (Celica)

Acoustic Control Induction System (ACIS) VSV is located on lower side of air cleaner case. See Fig. 2 . Remove necessary components for access to ACIS VSV. Remove ACIS VSV. To install, reverse removal procedure.

2002 ENGINE PERFORMANCE Removal, Overhaul & Installation - 4-Cylinder

Fig. 2: Locating Acoustic Control Induction System Vacuum Switching Valve & Components (Celica) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

COMPUTERIZED ENGINE CONTROLS

NOTE: When battery is disconnected, vehicle computer and memory systems may lose memory data. Driveability problems may exist until computer systems have completed a relearn cycle.

2002 ENGINE PERFORMANCE Removal, Overhaul & Installation - 4-Cylinder

NOTE:

On Camry and Celica, it may be possible that power sun roof may not operate properly if battery is disconnected and reconnected, or battery is discharged and recharged. If power sun roof does not operate properly, perform power sun roof reinitialization procedure. See appropriate POWER SUN ROOF REINITIALIZATION PROCEDURE under PROGRAMMING.

ENGINE CONTROL MODULE NOTE: On Camry, Camry Solara, Highlander, MR2 and RAV4, an engine immobilizer system may be used. On models equipped with engine immobilizer system, if Engine Control Module (ECM) is replaced, ECM must be programmed with proper ignition key code for engine immobilizer system. Models equipped with engine immobilizer system may be identified by looking at the ignition key. On models equipped with engine immobilizer system, the top of the ignition key is thicker than a standard ignition key, as a transponder chip is incorporated into the top of the ignition key. For programming procedures, see COMPUTER RELEARN PROCEDURES article in GENERAL INFORMATION, or appropriate ENGINE IMMOBILIZER SYSTEMS article in ACCESSORIES & EQUIPMENT.

Removal & Installation (Camry, Camry Solara, Celica, ECHO, Highlander, RAV4 & Tacoma)

Ensure ignition is off. Remove necessary components to access Engine Control Module (ECM). Remove ECM. See ECM LOCATION table. To install, reverse removal procedure.
Removal & Installation (Corolla)

Ensure ignition is off. Note location of Engine Control Module (ECM). See ECM LOCATION table. Remove lower center finish panel and necessary components for access to ECM. See Fig. 3 . Remove ECM. To install, reverse removal procedure.
Removal & Installation (MR2)

Ensure ignition is off. Note location of Engine Control Module (ECM). See ECM LOCATION table. Remove luggage compartment lids, luggage compartments, quarter trim panels, lower trim covers, partition board and cover for access to ECM. See Fig. 4 . For additional information on removal of luggage compartment components, see FUEL PUMP under FUEL SYSTEMS. Remove ECM. To install, reverse removal procedure.
Removal & Installation (Prius)

WARNING: Read service precautions before proceeding with service procedure. See SERVICE PRECAUTIONS . Ensure ignition is off. Remove necessary components to access Engine Control Module (ECM). Remove ECM. See ECM LOCATION table. To install, reverse removal procedure. ECM LOCATION Model
(1) Location

2002 ENGINE PERFORMANCE Removal, Overhaul & Installation - 4-Cylinder

Camry & Camry Solara Celica

Behind Glove Box In Engine Compartment, Below Cover, Just In Front Of Battery, Next To Driver's Side Strut Tower Corolla Behind Stereo On Instrument Panel, Just In Front Of Center Console ECHO & Highlander Behind Glove Box MR2 On Inside Of Firewall, Directly Behind Driver's Seat & Luggage Compartment Prius Behind Glove Box RAV4 Behind Passenger's Side Kick Panel, Just Below Instrument Panel Tacoma Behind Glove Box (1) For illustration of ECM location, see THEORY & OPERATION article.

2002 ENGINE PERFORMANCE Removal, Overhaul & Installation - 4-Cylinder

Fig. 3: Locating Engine Control Module & Components (Corolla) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 ENGINE PERFORMANCE Removal, Overhaul & Installation - 4-Cylinder

Fig. 4: Locating Engine Control Module & Components (MR2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

ENGINE SENSORS & SWITCHES

ACCELERATOR PEDAL POSITION SENSOR

2002 ENGINE PERFORMANCE Removal, Overhaul & Installation - 4-Cylinder

Removal & Installation (Camry)

Accelerator pedal position sensor is located near top of accelerator pedal. Service information is not available from manufacturer.
Removal & Installation (Camry Solara)

1. Accelerator pedal position sensor is located near top of accelerator pedal and must be replaced along with accelerator pedal as an assembly. See Fig. 5 . Disconnect electrical connector at accelerator pedal position sensor. Remove accelerator pedal bracket retaining bolts and accelerator pedal along with accelerator pedal position sensor. 2. To install, reverse removal procedure. Tighten accelerator pedal bracket retaining bolts to specification. See TORQUE SPECIFICATIONS .

Fig. 5: Locating Accelerator Pedal Position Sensor (Camry Solara) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Removal & Installation (MR2 With Sequential Manual Transaxle)

There are 2 types of manual transaxles used. On models with a standard type manual transaxle, the driver operates the clutch and shifts the transaxle. On models with sequential manual transaxle, the transaxle is

2002 ENGINE PERFORMANCE Removal, Overhaul & Installation - 4-Cylinder

electronically controlled and the clutch is operated and transaxle is shifted hydraulically by moving the shift lever forward or backward. Sequential manual transaxle may be identified by shift lever pattern which consists of "R", "N", "S" and "+" in place of the conventional type shift lever pattern and there is no clutch pedal. For servicing of accelerator pedal position sensor, see THROTTLE BODY under FUEL SYSTEMS.
Removal & Installation (Prius)

WARNING: Read service precautions before proceeding with service procedure. See SERVICE PRECAUTIONS . 1. Accelerator pedal position sensor is located near top of accelerator pedal and must be replaced along with accelerator pedal as an assembly. See Fig. 6 . Disconnect electrical connector at accelerator pedal position sensor. Remove accelerator pedal retaining bolts and accelerator pedal along with accelerator pedal position sensor. 2. To install, reverse removal procedure. Tighten accelerator pedal retaining bolts to specification. See TORQUE SPECIFICATIONS .

2002 ENGINE PERFORMANCE Removal, Overhaul & Installation - 4-Cylinder

Fig. 6: Locating Accelerator Pedal Position Sensor (Prius) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. A/C COMPRESSOR LOCK SENSOR
Removal & Installation (Camry, Camry Solara With Manual A/C, Celica, Highlander, MR2 & RAV4)

2002 ENGINE PERFORMANCE Removal, Overhaul & Installation - 4-Cylinder

A/C compressor lock sensor is located near front of A/C compressor with electrical connector located near generator. Service information is not available from manufacturer. It may be necessary to replace A/C compressor along with A/C compressor lock sensor as an assembly. Consult local parts department for parts availability. For servicing of A/C compressor, see appropriate article in AIR CONDITIONING & HEATING. A/C EVAPORATOR TEMPERATURE SENSOR
Removal & Installation (Camry With Manual A/C & Camry Solara With Manual A/C)

A/C evaporator temperature sensor is located in evaporator case, next to evaporator core. For servicing of A/C evaporator temperature sensor, see appropriate article in AIR CONDITIONING & HEATING. AIR/FUEL SENSOR NOTE: Air/Fuel (A/F) sensor may also be referred to as Air/Fuel (A/F) ratio sensor.

Removal & Installation (Camry, Camry Solara, Highlander & RAV4)

1. On Camry and Camry Solara, a heated Air/Fuel (A/F) sensor is mounted on exhaust manifold above catalytic converter. On Highlander and RAV4, there are 2 heated A/F sensors mounted on exhaust manifold above catalytic converter. On all models, disconnect electrical connector for A/F sensor. Remove heat insulator for access to A/F sensor. Unscrew A/F sensor from exhaust manifold. 2. To install, reverse removal procedure. Tighten A/F sensor to specification (if available). See TORQUE SPECIFICATIONS .
Removal & Installation (Tacoma)

1. Heated Air/Fuel (A/F) sensor is mounted on exhaust pipe in front of catalytic converter. Disconnect electrical connector for A/F sensor. Remove retaining nuts, A/F sensor and gasket from exhaust pipe. 2. To install, reverse removal procedure using NEW gasket. Tighten A/F sensor retaining nuts to specification. See TORQUE SPECIFICATIONS . AIRFLOW METER NOTE: Airflow meter may be referred to as Mass Airflow (MAF) meter.

Removal & Installation (Camry, Camry Solara, Celica, Corolla, ECHO, Highlander, MR2, Prius & RAV4)

WARNING: On Prius, read service precautions before proceeding with service procedure. See SERVICE PRECAUTIONS . Ensure ignition is off. Disconnect electrical connector at airflow meter. Airflow meter is bolted to upper cap on air cleaner assembly. Remove bolts, airflow meter and "O" ring. To install reverse removal procedure using NEW "O" ring.
Removal & Installation (Tacoma)

1. Ensure ignition is off. Disconnect electrical connector at airflow meter. Airflow meter is located

2002 ENGINE PERFORMANCE Removal, Overhaul & Installation - 4-Cylinder

between air intake hose and upper cap on air cleaner assembly and is mounted on upper cap on air cleaner assembly. 2. Disconnect necessary hoses for removal of upper cap on air cleaner assembly. Loosen clamp on air intake hose at airflow meter. Loosen retaining clips that retain upper cap on air cleaner assembly. 3. Remove upper cap on air cleaner assembly with airflow meter from air cleaner assembly. Remove airflow meter retaining nuts, airflow meter and gasket from upper cap. 4. To install, reverse removal procedure using NEW gasket. Tighten airflow meter retaining nuts to specification. See TORQUE SPECIFICATIONS . BRAKELIGHT SWITCH NOTE: Brakelight switch may also be referred to as stoplight switch.

Removal & Installation (Camry)

1. Remove necessary components for access to brakelight switch. Brakelight switch is located near top of brake pedal. Disconnect electrical connector at brakelight switch. Loosen lock nut on brakelight switch. Remove brakelight switch from mounting bracket. 2. Install brakelight switch in mounting bracket. Install electrical connector on brakelight switch. Depress brake pedal .20-.39" (5.0-10.0 mm) and hold in this position. Rotate brakelight switch inward until stoplights go off. Tighten lock nut. Release brake pedal. 3. Depress brake pedal .20-.39" (5.0-10.0 mm) and ensure brakelights come on. Release brake pedal. Ensure brakelights go off.
Removal & Installation (Camry Solara, Corolla, ECHO, Highlander, MR2, Prius & RAV4

WARNING: On Prius, read service precautions before proceeding with service procedure. See SERVICE PRECAUTIONS . 1. Remove necessary components for access to brakelight switch. Brakelight switch is located near top of brake pedal. Disconnect electrical connector at brakelight switch. Loosen lock nut on brakelight switch. Remove brakelight switch from mounting bracket. 2. Install brakelight switch in mounting bracket. Install electrical connector on brakelight switch. Depress brake pedal .20-.59" (5.0-15.0 mm) and hold in this position. Rotate brakelight switch inward until stoplights go off. Tighten lock nut. Release brake pedal. 3. Depress brake pedal .20-.59" (5.0-15.0 mm) and ensure brakelights come on. Release brake pedal. Ensure brakelights go off.
Removal & Installation (Celica)

1. Remove necessary components for access to brakelight switch. Brakelight switch is located near top of brake pedal. Disconnect electrical connector at brakelight switch. Rotate brakelight switch counterclockwise and remove brakelight switch from mounting bracket. 2. Install brakelight switch in mounting bracket until brakelight switch contacts the cushion. Rotate brakelight switch clockwise approximately 1/4 turn to install brakelight switch in mounting bracket. Using feeler gauge, measure clearance between cushion and brakelight switch to determine the protrusion of the rod on brakelight switch. See Fig. 7 . Clearance should be .020-.102" (.50-2.60 mm). Depress brake pedal and ensure brakelights come on. Release brake pedal. Ensure brakelights go off.

2002 ENGINE PERFORMANCE Removal, Overhaul & Installation - 4-Cylinder

Fig. 7: Measuring Clearance At Brakelight Switch (Celica) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Removal & Installation (Tacoma)

Brakelight switch is located near top of brake pedal. Service information is not available from manufacturer. CAMSHAFT POSITION SENSOR NOTE: On Camry, Camry Solara, Celica, Corolla, ECHO, Highlander, MR2, Prius and RAV4, camshaft position sensor may also be referred to Variable Valve Timing (VVT) sensor.

Removal & Installation

See CAMSHAFT POSITION SENSOR under IGNITION SYSTEMS. CRANKSHAFT POSITION SENSOR
Removal & Installation

See CRANKSHAFT POSITION SENSOR under IGNITION SYSTEMS.

2002 ENGINE PERFORMANCE Removal, Overhaul & Installation - 4-Cylinder

EGR GAS TEMPERATURE SENSOR

Removal & Installation (Tacoma 2.7L 4-Cyl. 3RZ-FE)

1. Disconnect electrical connector at EGR gas temperature sensor. EGR gas temperature sensor is located near EGR valve. See Fig. 8 . 2. It may be necessary to remove EGR valve for access to EGR gas temperature sensor. See EGR VALVE under EMISSION SYSTEMS & SUB-SYSTEMS. Remove EGR gas temperature sensor. To install, reverse removal procedure.

Fig. 8: Locating EGR Gas Temperature Sensor (Tacoma 2.7L 4-Cyl. 3RZ-FE) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ENGINE COOLANT TEMPERATURE SENSOR
Removal & Installation (Camry, Camry Solara, Corolla, Highlander, RAV4 & Tacoma)

1. Ensure ignition is off. Disconnect electrical connector at Engine Coolant Temperature (ECT) sensor. See ENGINE COOLANT TEMPERATURE SENSOR LOCATION table.

2002 ENGINE PERFORMANCE Removal, Overhaul & Installation - 4-Cylinder

2. Drain cooling system. Remove ECT sensor and gasket. To install, reverse removal procedure using NEW gasket. Tighten ECT sensor to specification (if available). See TORQUE SPECIFICATIONS . Fill cooling system.
Removal & Installation (Celica)

1. Ensure ignition is off. Remove No. 2 cylinder head cover located on top of engine, above ignition coils and valve cover. Disconnect electrical connector at Engine Coolant Temperature (ECT) sensor. See ENGINE COOLANT TEMPERATURE SENSOR LOCATION table. 2. Drain cooling system. Remove ECT sensor and gasket. To install, reverse removal procedure using NEW gasket. Reinstall No. 2 cylinder head cover. Fill and bleed cooling system. See COOLING SYSTEM BLEEDING under COOLING SYSTEM.
Removal & Installation (ECHO)

1. Ensure ignition is off. Remove No. 2 cylinder head cover located on top of engine, above ignition coils and valve cover. Remove air cleaner assembly for access to Engine Coolant Temperature (ECT) sensor. See ENGINE COOLANT TEMPERATURE SENSOR LOCATION table. Disconnect electrical connector at ECT sensor. 2. Drain cooling system. Remove ECT sensor and gasket. To install, reverse removal procedure using NEW gasket. Reinstall air cleaner assembly and No. 2 cylinder head cover. Fill cooling system.
Removal & Installation (MR2)

1. Ensure ignition is off. Disconnect electrical connector at Engine Coolant Temperature (ECT) sensor. See ENGINE COOLANT TEMPERATURE SENSOR LOCATION table. 2. Drain cooling system. Remove ECT sensor and gasket. To install, reverse removal procedure using NEW gasket. Tighten ECT sensor to specification. See TORQUE SPECIFICATIONS . Fill and bleed cooling system. See COOLING SYSTEM BLEEDING under COOLING SYSTEM. ENGINE COOLANT TEMPERATURE SENSOR LOCATION Model Location Camry & Camry On Flywheel End Of Cylinder Head & Solara Contains Dark Gray Electrical Connector With Green/Yellow & Brown Wires Celica On Flywheel End Of Cylinder Head & Contains Gray Electrical Connector With Green & Brown Wires Corolla On Flywheel End Of Cylinder Head & Contains Dark Gray Electrical Connector With White & Brown Wires ECHO On Flywheel End Of Cylinder Head & Contains Gray Electrical Connector With Red/Blue & Brown Wires Highlander On Flywheel End Of Cylinder Head & Contains Dark Gray 2-Pin Electrical Connector With White/Blue & White Wires MR2 On Flywheel End Of Cylinder Head & Contains Dark Gray 2-Pin Electrical

2002 ENGINE PERFORMANCE Removal, Overhaul & Installation - 4-Cylinder

RAV4

Tacoma

Connector With Red/Blue & Brown Wires On Flywheel End Of Cylinder Head & Contains Dark Gray 2-Pin Electrical Connector With White & Brown Wires On Coolant Housing At Rear Of Cylinder Head & Contains Dark Gray 2-Pin Electrical Connector With Green/Red & Blue/Black Wires

Removal & Installation (Prius)

WARNING: Service procedure should only be performed by authorized dealer.

ECT sensor is located on flywheel end of cylinder head and contains a Dark Gray 2-pin electrical connector with White and Brown wires. Manufacturer states that converter and inverter assembly must be removed for access to ECT sensor. The converter and inverter assembly are involved with the high-voltage system used on this vehicle and service procedure should only be performed by authorized dealer. HEATED OXYGEN SENSOR NOTE: On Camry, Camry Solara, Highlander, RAV4 and Tacoma, an Air/Fuel (A/F) sensor is used. For servicing of A/F sensor, see AIR/FUEL SENSOR .

Removal & Installation (All Models)

WARNING: On Prius, read service precautions before proceeding with service procedure. See SERVICE PRECAUTIONS . 1. Servicing of heated oxygen sensor is just primarily an unbolt and bolt-on procedure. For heated oxygen sensor location, see HEATED OXYGEN SENSOR LOCATION table. It may be necessary to remove heat insulator for access to heated oxygen sensor. On MR2, it may be necessary to remove air cleaner assembly for access to heated oxygen sensor on exhaust pipe assembly. 2. On all models, disconnect electrical connector for heated oxygen sensor. Remove retaining nuts or unscrew heated oxygen sensor. Remove heated oxygen sensor and gasket (if equipped). To install, reverse removal procedure using NEW gasket (if equipped). Tighten heated oxygen sensor or retaining nuts to specification (if available). See TORQUE SPECIFICATIONS . HEATED OXYGEN SENSOR LOCATION Model Location Camry & Camry On Exhaust Pipe After Catalytic Converter Solara Celica, Corolla One On Exhaust Pipe In Front Of Catalytic & ECHO Converter & One On Exhaust Pipe After Catalytic Converter Highlander Two Oxygen Sensors Are Mounted On Exhaust Manifold Below Catalytic Converters

2002 ENGINE PERFORMANCE Removal, Overhaul & Installation - 4-Cylinder

MR2

Prius

RAV4

Tacoma IGNITION SWITCH

Two Oxygen Sensors Are Mounted On Exhaust Manifold Above Catalytic Converters & One On Exhaust Pipe Behind Catalytic Converter One On Exhaust Pipe In Front Of Catalytic Converter & One On Exhaust Pipe After Catalytic Converter Two Oxygen Sensors Are Mounted On Exhaust Manifold Below Catalytic Converters On Exhaust Pipe After Catalytic Converter

Removal & Installation (All Models)

Ignition switch is located at bottom of upper steering column bracket. See Fig. 9 . If necessary to remove steering column for access to ignition switch, see appropriate STEERING COLUMNS article in STEERING. Remove screws and ignition switch. To install, reverse removal procedure.

2002 ENGINE PERFORMANCE Removal, Overhaul & Installation - 4-Cylinder

Fig. 9: Locating Typical Ignition Switch Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. KNOCK SENSOR NOTE: Knock sensor may also be referred to as knock sensor No. 1.

Removal & Installation (Camry)

Knock sensor is located on side of cylinder block, just below intake manifold. See Fig. 10 . Service information is not available from manufacturer. It may be necessary to remove engine with transaxle to gain access for removal of intake manifold. For engine removal, see appropriate article in ENGINES. It may be necessary to remove intake manifold for access to knock sensor. Use Socket (SST 09816-30010) when servicing knock sensor. Tighten knock sensor and intake manifold bolts/nuts (if removed) to specification. See TORQUE SPECIFICATIONS .

2002 ENGINE PERFORMANCE Removal, Overhaul & Installation - 4-Cylinder

Fig. 10: Locating Knock Sensor (Camry & Highlander) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Removal (Camry Solara)

1. Knock sensor is located on side of cylinder block. See Fig. 11 . Manufacturer states to remove engine with transaxle for access to knock sensor. See appropriate article in ENGINES. 2. Disconnect necessary hoses for removal of intake manifold with throttle body. Remove engine wiring harness from engine wiring harness clamp. Remove bolts/nuts, engine wiring harness brackets, intake manifold with throttle body, gasket and intake manifold insulator. See Fig. 11 . Using Socket (SST 09816-30010), remove knock sensor from cylinder block.
Installation

Install and tighten knock sensor to specification. See TORQUE SPECIFICATIONS . To install intake manifold, reverse removal procedure using NEW gasket. Tighten intake manifold bolts/nuts to specification. See TORQUE SPECIFICATIONS . Reinstall engine.

2002 ENGINE PERFORMANCE Removal, Overhaul & Installation - 4-Cylinder

Fig. 11: Locating Knock Sensor & Identifying Intake Manifold & Components (Camry Solara) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Removal (Celica)

1. Manufacturer states throttle body and intake manifold must be removed for access to knock sensor. Knock sensor is located on side of cylinder block. See Fig. 12 and Fig. 13 . Remove throttle body. See

2002 ENGINE PERFORMANCE Removal, Overhaul & Installation - 4-Cylinder

THROTTLE BODY under FUEL SYSTEMS. 2. Remove coolant reservoir and air cleaner case. Disconnect necessary hoses for removal of intake manifold. On 1.8L 2ZZ-GE models, remove bolts/nuts and intake manifold support from rear of intake manifold. On all models, remove bolts/nuts, intake manifold and gasket from cylinder head. 3. Disconnect electrical connector at knock sensor. On 1.8L 1ZZ-FE models, using Socket (SST 0981630010), remove knock sensor from cylinder block. On 1.8L 2ZZ-GE models, note position electrical connector fitting on knock sensor in relation to the cylinder block for installation reference. Remove knock sensor retaining nut from stud at center of knock sensor. See Fig. 13 . Remove knock sensor from stud on cylinder block.
Installation

1. On 1.8L 1ZZ-FE models, install and tighten knock sensor to specification. See TORQUE SPECIFICATIONS . On 1.8L 2ZZ-GE models, install knock sensor on stud on cylinder block. Ensure electrical connector fitting on knock sensor is positioned in original location in relation to the cylinder block. Install and tighten knock sensor retaining nut to specification. See TORQUE SPECIFICATIONS . On all models, reinstall electrical connector on knock sensor. To install remaining components, reverse removal procedure using NEW gaskets. 2. On 1.8L 2ZZ-GE models, note intake manifold bolt/nut identification before tightening intake manifold bolts/nuts to specification. See Fig. 14 . On all models, ensure gasket for throttle body is installed with protrusion area facing proper direction. See THROTTLE BODY under FUEL SYSTEMS. Tighten bolts/nuts to specification. See TORQUE SPECIFICATIONS . Fill and bleed cooling system. See COOLING SYSTEM BLEEDING under COOLING SYSTEM.

2002 ENGINE PERFORMANCE Removal, Overhaul & Installation - 4-Cylinder

Fig. 12: Locating Knock Sensor & Identifying Intake Manifold & Components (Celica 1.8L

2002 ENGINE PERFORMANCE Removal, Overhaul & Installation - 4-Cylinder

1ZZ-FE) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 13: Locating Knock Sensor & Identifying Intake Manifold & Components (Celica 1.8L 2ZZ-GE) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 ENGINE PERFORMANCE Removal, Overhaul & Installation - 4-Cylinder

Fig. 14: Identifying Intake Manifold Bolts/Nuts (Celica 1.8L 2ZZ-GE) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Removal (Corolla)

1. Manufacturer states throttle body and intake manifold must be removed for access to knock sensor. Knock sensor is located on side of cylinder block. See Fig. 15 . Remove throttle body. See THROTTLE BODY under FUEL SYSTEMS. 2. Remove No. 2 cylinder head cover located on top of engine, above ignition coils and valve cover. See Fig. 15 . Disconnect necessary electrical connectors so engine wiring harness protector and engine wiring harness may be disconnected from engine wiring harness brackets. See Fig. 15 . 3. Remove bolts and disconnect engine wiring harness protector and engine wiring harness from engine wiring harness brackets. Disconnect necessary hoses for removal of intake manifold. Remove bolts from intake manifold support. Remove bolts/nuts, engine wiring harness brackets, intake manifold and gasket from cylinder head. 4. Disconnect electrical connector at knock sensor. Using Socket (SST 09816-30010), remove knock sensor from cylinder block.
Installation

Install and tighten knock sensor to specification. See TORQUE SPECIFICATIONS . To install remaining

2002 ENGINE PERFORMANCE Removal, Overhaul & Installation - 4-Cylinder

components, reverse removal procedure using NEW gaskets. Ensure gasket for throttle body is installed with protrusion area facing proper direction. See THROTTLE BODY under FUEL SYSTEMS. Tighten bolts/nuts to specification. See TORQUE SPECIFICATIONS . Fill cooling system.

Fig. 15: Locating Knock Sensor & Identifying Intake Manifold & Components (Corolla) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Removal (ECHO)

2002 ENGINE PERFORMANCE Removal, Overhaul & Installation - 4-Cylinder

1. Manufacturer states throttle body and intake manifold must be removed for access to knock sensor. Knock sensor is located on side of cylinder block. See Fig. 16 . Remove throttle body. See THROTTLE BODY under FUEL SYSTEMS. 2. Remove coolant filler and No. 2 cylinder head cover located on top of engine, above ignition coils and valve cover (if necessary) for access to intake manifold. See Fig. 16 . Disconnect necessary hoses for removal of intake manifold. Remove bolts/nuts, intake manifold and gasket from cylinder head. 3. Disconnect electrical connector at knock sensor. Using Socket (SST 09816-30010), remove knock sensor from cylinder block.
Installation

Install and tighten knock sensor to specification. See TORQUE SPECIFICATIONS . To install remaining components, reverse removal procedure using NEW gaskets. Tighten bolts/nuts to specification. See TORQUE SPECIFICATIONS . Fill cooling system.

2002 ENGINE PERFORMANCE Removal, Overhaul & Installation - 4-Cylinder

Fig. 16: Locating Knock Sensor & Identifying Intake Manifold & Components (ECHO) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Removal & Installation (Highlander)

2002 ENGINE PERFORMANCE Removal, Overhaul & Installation - 4-Cylinder

Knock sensor is located on side of cylinder block, just below intake manifold. See Fig. 10 . Service information is not available from manufacturer. It may be necessary to remove engine with transaxle to gain access for removal of intake manifold. For engine removal, see appropriate article in ENGINES. It may be necessary to remove intake manifold for access to knock sensor. Use Socket (SST 09816-30010) when servicing knock sensor. Tighten knock sensor and intake manifold bolts/nuts (if removed) to specification. See TORQUE SPECIFICATIONS .
Removal (MR2)

1. Knock sensor is located on side of cylinder block. See Fig. 17 . Manufacturer states to remove engine and transaxle for access to knock sensor. See appropriate article in ENGINES. 2. Disconnect coolant hoses from throttle body and vacuum hoses from intake manifold. Remove engine wiring harness from engine wiring harness brackets. Remove bolts/nuts, engine wiring harness brackets, intake manifold with throttle body and gasket. Using Socket (SST 09817-16011), remove knock sensor from cylinder block.
Installation

Install and tighten knock sensor to specification. See TORQUE SPECIFICATIONS . To install intake manifold, reverse removal procedure using NEW gasket. Tighten intake manifold bolts/nuts to specification. See TORQUE SPECIFICATIONS . Reinstall engine. Fill and bleed cooling system. See COOLING SYSTEM BLEEDING under COOLING SYSTEM.

2002 ENGINE PERFORMANCE Removal, Overhaul & Installation - 4-Cylinder

Fig. 17: Locating Knock Sensor & Identifying Typical Intake Manifold & Components (MR2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Removal (Prius)

WARNING: Read service precautions before proceeding with service procedure. See SERVICE PRECAUTIONS . 1. Manufacturer states throttle body and intake manifold must be removed for access to knock sensor.

2002 ENGINE PERFORMANCE Removal, Overhaul & Installation - 4-Cylinder

Knock sensor is located on side of cylinder block. See Fig. 18 . 2. Ensure service plug is removed from service plug assembly. See SERVICE PRECAUTIONS . Remove throttle body. See THROTTLE BODY under FUEL SYSTEMS. Remove engine oil dipstick and tube with "O" ring if necessary for access to intake manifold. 3. Remove bolts/nuts, intake manifold and gasket from cylinder head. Disconnect electrical connector at knock sensor. Using Socket (SST 09816-30010), remove knock sensor from cylinder block.
Installation

Install and tighten knock sensor to specification. See TORQUE SPECIFICATIONS . To install remaining components, reverse removal procedure using NEW gaskets and "O" ring on dipstick tube. Tighten bolts/nuts to specification. See TORQUE SPECIFICATIONS . Fill and bleed cooling system. See COOLING SYSTEM BLEEDING under COOLING SYSTEM.

2002 ENGINE PERFORMANCE Removal, Overhaul & Installation - 4-Cylinder

Fig. 18: Locating Knock Sensor & Identifying Intake Manifold & Components (Prius) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Removal (RAV4)

1. Knock sensor is located on side of cylinder block. See Fig. 19 . Manufacturer states to remove engine and transaxle for access to knock sensor. See appropriate article in ENGINES. 2. Disconnect necessary hoses, electrical connectors and engine wiring harness for removal of intake manifold with throttle body. Remove bolts/nuts, intake manifold with throttle body, gasket and intake manifold insulator. Using Socket (SST 09816-30010), remove knock sensor from cylinder block.
Installation

2002 ENGINE PERFORMANCE Removal, Overhaul & Installation - 4-Cylinder

Install and tighten knock sensor to specification. See TORQUE SPECIFICATIONS . To install intake manifold, reverse removal procedure using NEW gasket. Tighten intake manifold bolts/nuts to specification. See TORQUE SPECIFICATIONS . Reinstall engine.

Fig. 19: Locating Knock Sensor & Identifying Intake Manifold & Components (RAV4)

2002 ENGINE PERFORMANCE Removal, Overhaul & Installation - 4-Cylinder

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Removal & Installation (Tacoma)

1. Remove starter and fuel filter mounting bolts to access knock sensor. Knock sensor is located on side of cylinder block. See Fig. 20 . 2. Disconnect electrical connector at knock sensor. Using Socket (SST 09816-30010), remove knock sensor from cylinder block. 3. To install, reverse removal procedure. Tighten knock sensor, fuel filter mounting bolts and starter bolts to specification. See TORQUE SPECIFICATIONS .

Fig. 20: Locating Knock Sensor (Tacoma) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. PARK/NEUTRAL POSITION SWITCH NOTE: Park/Neutral Position (PNP) is used only on A/T models.

Removal (Camry, Camry Solara, Celica, Corolla, ECHO, Highlander & RAV4)

1. The Park/Neutral Position (PNP) switch is located on side of transaxle. See Fig. 21 . Remove necessary components for access to PNP switch. 2. Disconnect electrical connector at PNP switch. Disconnect shift cable on transaxle for access to PNP

2002 ENGINE PERFORMANCE Removal, Overhaul & Installation - 4-Cylinder

switch. Remove nut, washer and control lever from transaxle. 3. Bend tabs upward on lock plate, away from PNP switch retaining nut. Remove PNP switch retaining nut, lock plate, PNP switch retaining bolts and PNP switch.
Installation

1. Using NEW lock plate, install PNP switch on transaxle. Install and tighten PNP switch retaining nut and PNP switch retaining bolts to specification. See TORQUE SPECIFICATIONS . Bend over tab on lock plate against PNP switching retaining nut. 2. Reinstall control lever, washer and nut on PNP switch. Tighten nut for control lever to specification. See TORQUE SPECIFICATIONS . Reconnect shift cable on control lever. Check that engine starts only with shift lever in Park and Neutral. If PNP switch adjustment is required, go to next step. 3. Ensure parking brake is applied. Place shift lever in Neutral. It may be necessary to remove control lever for access to PNP switch retaining bolts. Loosen PNP switch retaining bolts. 4. Rotate PNP switch so neutral base line aligns with the groove. See Fig. 22 -Fig. 26 . Tighten PNP switch retaining bolts to specification. See TORQUE SPECIFICATIONS . 5. Ensure continuity exists between specified terminals on PNP switch in relation to shift lever position. See PARK/NEUTRAL POSITION SWITCH under ENGINE SENSORS & SWITCHES in SYSTEM & COMPONENT TESTING - 4-CYLINDER article. Reinstall electrical connector.

Fig. 21: Locating Typical Park/Neutral Position Switch & Components Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 ENGINE PERFORMANCE Removal, Overhaul & Installation - 4-Cylinder

Fig. 22: Adjusting Park/Neutral Position Switch (Camry, Camry Solara, Highlander & RAV4) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 ENGINE PERFORMANCE Removal, Overhaul & Installation - 4-Cylinder

Fig. 23: Adjusting Park/Neutral Position Switch (Celica 1.8L 1ZZ-FE & ECHO) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 ENGINE PERFORMANCE Removal, Overhaul & Installation - 4-Cylinder

Fig. 24: Adjusting Park/Neutral Position Switch (Celica 1.8L 2ZZ-GE) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 ENGINE PERFORMANCE Removal, Overhaul & Installation - 4-Cylinder

Fig. 25: Adjusting Park/Neutral Position Switch (Corolla With 3-Speed A/T) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 ENGINE PERFORMANCE Removal, Overhaul & Installation - 4-Cylinder

Fig. 26: Adjusting Park/Neutral Position Switch (Corolla With 4-Speed A/T) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Removal (Tacoma)

1. The Park/Neutral Position (PNP) switch is located on side of transmission. See Fig. 21 . Remove front exhaust pipe with heat insulator (if necessary) and disconnect transmission oil cooler line for access to PNP switch. 2. Remove transmission oil cooler line elbow with "O" ring for access to PNP switch (if necessary). Disconnect electrical connector at PNP switch. 3. Bend tabs upward on lock plate, away from PNP switch retaining nut. Remove PNP switch retaining nut, lock plate, PNP switch retaining bolt and PNP switch.
Installation

1. Using NEW lock plate, install PNP switch on transmission. Install and tighten PNP switch retaining nut and PNP switch retaining bolt to specification. See TORQUE SPECIFICATIONS . Bend over tab on lock plate against PNP switching retaining nut.

2002 ENGINE PERFORMANCE Removal, Overhaul & Installation - 4-Cylinder

2. Using NEW "O" ring, install transmission oil cooler line elbow (if removed) and tighten to specification. See TORQUE SPECIFICATIONS . Install transmission oil cooler line (if removed) and tighten nut to specification. See TORQUE SPECIFICATIONS . 3. Check that engine starts only with shift lever in Park and Neutral. If PNP switch adjustment is required, go to next step. 4. Ensure parking brake is applied. Place shift lever in Neutral. Loosen PNP switch retaining bolt. Rotate PNP switch so neutral base line aligns with the groove. See Fig. 27 and Fig. 28 . Tighten PNP switch retaining bolt to specification. See TORQUE SPECIFICATIONS . 5. Ensure continuity exists between specified terminals on PNP switch in relation to shift lever position. See PARK/NEUTRAL POSITION SWITCH under ENGINE SENSORS & SWITCHES in SYSTEM & COMPONENT TESTING - 4-CYLINDER article. Reinstall electrical connector.

Fig. 27: Adjusting Park/Neutral Position Switch (Tacoma 2.4L 2RZ-FE) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 ENGINE PERFORMANCE Removal, Overhaul & Installation - 4-Cylinder

Fig. 28: Adjusting Park/Neutral Position Switch (Tacoma 2.7L 3RZ-FE) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. POSITIVE TEMPERATURE COEFFICIENT HEATER
Removal & Installation (ECHO)

Positive Temperature Coefficient (PTC) heater is located in the heater core. See Fig. 29 . For servicing of PTC heater, see appropriate HEATER SYSTEMS article in AIR CONDITIONING & HEATING.

2002 ENGINE PERFORMANCE Removal, Overhaul & Installation - 4-Cylinder

Fig. 29: Locating Positive Temperature Coefficient Heater (ECHO) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. POWER STEERING PRESSURE SENSOR NOTE: Power steering pressure sensor may also be referred to as power steering oil pressure sensor.

Removal & Installation (ECHO)

1. Power steering pressure sensor is located on side of power steering pump and contains a 3-pin electrical connector. Disconnect electrical connector at power steering pressure sensor. Remove power steering pressure sensor with "O" ring from power steering pump. 2. To install, reverse removal procedure using NEW "O" ring. Coat "O" ring with Dexron-III ATF before installing power steering pressure sensor. Tighten power steering pressure sensor to specification. See TORQUE SPECIFICATIONS . Fill power steering pump with Dexron-III ATF.

2002 ENGINE PERFORMANCE Removal, Overhaul & Installation - 4-Cylinder

POWER STEERING PRESSURE SWITCH NOTE: Power steering pressure switch may also be referred to as power steering oil pressure switch. CAUTION: When servicing power steering pressure switch, use care not to drop power steering pressure switch or switch may be damaged.
Removal & Installation (Camry, Camry Solara, Celica, Highlander & RAV4)

1. Power steering pressure switch is screwed into side of power steering pump, near pressure hose fitting. It may be necessary to remove power steering pump for access to power steering pressure switch. Disconnect electrical connector at power steering pressure switch. Remove power steering pressure switch with "O" ring (if equipped) from power steering pump. 2. To install, reverse removal procedure using NEW "O" ring (if equipped). Coat "O" ring with DexronIII ATF before installing power steering pressure switch. Tighten power steering pressure switch to specification. See TORQUE SPECIFICATIONS . Fill power steering pump with Dexron-III ATF.
Removal & Installation (Corolla)

1. Power steering pressure switch is screwed into end of union bolt that secures pressure hose on power steering pump. Disconnect electrical connector at power steering pressure switch. Remove power steering pressure switch. 2. To install, reverse removal procedure. Tighten power steering pressure switch to specification. See TORQUE SPECIFICATIONS . Fill power steering pump with Dexron-III ATF.
Removal & Installation (Tacoma)

Service information is not available from manufacturer. THROTTLE POSITION SENSOR NOTE: On MR2, there are 2 types of throttle bodies and TP sensors used depending on type of transaxle used. On models with a standard type manual transaxle, the driver operates the clutch and shifts the transaxle. On models with sequential manual transaxle, the transaxle is electronically controlled and the clutch is operated and transaxle is shifted hydraulically by moving the shift lever forward or backward. Sequential manual transaxle may be identified by shift lever pattern which consists of "R", "N", "S" and "+" in place of the conventional type shift lever pattern and no clutch pedal is used.

Removal & Installation (Camry & Camry Solara)

Throttle Position (TP) sensor is incorporated into the throttle body. Service information is not available from manufacturer.
Removal & Installation (Celica, Corolla, ECHO, MR2 With Standard Type Manual Transaxle, RAV4 & Tacoma)

2002 ENGINE PERFORMANCE Removal, Overhaul & Installation - 4-Cylinder

Throttle Position (TP) sensor is mounted on throttle body. Service information is not available from manufacturer.
Removal & Installation (Highlander)

1. Throttle Position (TP) sensor is mounted on throttle body. Manufacturer lists procedure with throttle body removed. If necessary to remove throttle body for access to TP sensor, see THROTTLE BODY under FUEL SYSTEMS. Remove retaining screws and TP sensor from throttle body. 2. To install, ensure throttle valve on throttle body is fully closed. Position TP sensor at 45 degrees so it aligns with shaft on throttle valve and install on throttle body. See Fig. 30 . Rotate TP sensor to the right 45 degress. Install and tighten retaining screws.

Fig. 30: Installing Throttle Position Sensor (Highlander) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Removal & Installation (MR2 With Sequential Manual Transaxle & Prius)

For servicing of Throttle Position (TP) sensor, see THROTTLE BODY under FUEL SYSTEMS. VACUUM SENSOR FOR HYDROCARBON ADSORBER CATALYST SYSTEM
Removal & Installation (Prius)

WARNING: Read service precautions before proceeding with service procedure.

2002 ENGINE PERFORMANCE Removal, Overhaul & Installation - 4-Cylinder

See SERVICE PRECAUTIONS . Vacuum for sensor for Hydrocarbon Adsorber Catalyst (HCAC) system is located at passenger's side front corner of the engine and contains Black 3-pin connector with Brown, Violet/White and Yellow/Red wires. See Fig. 31 . Servicing of vacuum sensor is just primarily an unbolt and bolt-on procedure.

Fig. 31: Locating Vacuum Sensor For HCAC System (Prius) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. VAPOR PRESSURE SENSOR
Removal & Installation

2002 ENGINE PERFORMANCE Removal, Overhaul & Installation - 4-Cylinder

For servicing of vapor pressure sensor, see VAPOR PRESSURE SENSOR under EMISSION SYSTEMS & SUB-SYSTEMS. VARIABLE VALVE TIMING SENSOR NOTE: Variable Valve Timing (VVT) sensor may also be referred to as camshaft position sensor.

Removal & Installation (Camry, Camry Solara, Celica, Corolla, ECHO, Highlander, MR2, Prius & RAV4)

For VVT sensor servicing, see CAMSHAFT POSITION SENSOR under IGNITION SYSTEMS. VEHICLE SPEED SENSOR
Removal & Installation (Camry)

Vehicle speed sensor is mounted on transaxle and contains a Black 3-pin electrical connector with Blue, Pink and Red/Blue wires. Service information is not available from manufacturer.
Removal (Camry Solara, Celica, Corolla, ECHO & RAV4)

1. Vehicle speed sensor is mounted on transaxle and contains a 3-pin electrical connector. See Fig. 32 . Remove necessary components for access to vehicle speed sensor. Disconnect electrical connector at vehicle speed sensor. 2. Remove retaining bolt and vehicle speed sensor with "O" ring from transaxle. If necessary to remove drive gear assembly from vehicle speed sensor, remove retaining clip from outside of vehicle speed sensor. Retaining clip is located just below "O" ring groove on vehicle speed sensor. Remove drive gear from vehicle speed sensor.
Installation

To install, reverse removal procedure using NEW "O" ring. Coat "O" ring with Dexron-III ATF (A/T models) or gear oil (M/T models) before installing on vehicle speed sensor. Tighten retaining bolt to specification. See TORQUE SPECIFICATIONS .

2002 ENGINE PERFORMANCE Removal, Overhaul & Installation - 4-Cylinder

Fig. 32: Locating Typical Vehicle Speed Sensor (Camry Solara, Celica, Corolla, ECHO & RAV4) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Removal & Installation (Highlander)

Vehicle speed sensor is not used. Wheel speed sensors on each wheel deliver an input signal to skid control Electronic Control Unit (ECU). Skid control ECU converts input signals from wheel speed sensors to a 4pulse input signal to the instrument cluster. Instrument cluster then converts 4-pulse input signal to a rectangular waveform and then sends input signal to Engine Control Module (ECM). ECM determines vehicle speed by using input signal.
Removal & Installation (MR2)

Vehicle speed sensor is not used. Wheel speed sensors on each wheel deliver an input signal to Anti-Lock Brake System (ABS) Electronic Control Unit (ECU). ABS ECU converts input signals from wheel speed sensors to a 4-pulse input signal to the instrument cluster. Instrument cluster then converts 4-pulse input

2002 ENGINE PERFORMANCE Removal, Overhaul & Installation - 4-Cylinder

signal to a rectangular waveform and then sends input signal to Engine Control Module (ECM). ECM determines vehicle speed by using input signal.
Removal & Installation (Prius)

Vehicle speed sensor is not used. Wheel speed sensors on each wheel deliver an input signal to brake Electronic Control Unit (ECU) for the Anti-Lock Brake System (ABS). Brake ECU converts input signals from wheel speed sensors to a 4-pulse input signal to the instrument cluster. Instrument cluster then converts 4-pulse input signal to a rectangular waveform and then sends input signal to Engine Control Module (ECM). ECM determines vehicle speed by using input signal.
Removal (Tacoma)

1. Vehicle speed sensor is mounted near rear of transmission or transfer case and contains a 3-pin electrical connector with Blue, Green/Red and Pink wires. See Fig. 33 . 2. Disconnect electrical connector at vehicle speed sensor. Remove retaining bolt and vehicle speed sensor with "O" ring. Remove drive gear from vehicle speed sensor (if necessary).
Installation

To install, reverse removal procedure using NEW "O" ring. Coat "O" ring with Dexron-III ATF (A/T models) or gear oil (M/T models) before installing on vehicle speed sensor. Tighten retaining bolt to specification. See TORQUE SPECIFICATIONS .

2002 ENGINE PERFORMANCE Removal, Overhaul & Installation - 4-Cylinder

Fig. 33: Locating Typical Vehicle Speed Sensor (Tacoma) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

COOLING SYSTEM
COOLING SYSTEM BLEEDING NOTE: On Celica, MR2 and Prius, whenever cooling system is drained, special cooling system bleeding procedure must be performed. On all other models, no special cooling system bleeding procedure is required.

Celica

1. This procedure assumes cooling system has been completely drained by loosening radiator drain plug on bottom of radiator and engine drain plug on coolant drain union located on driver's side rear corner of cylinder block. 2. Remove front fender apron seal and upper radiator support seal for access to coolant reservoir. See Fig. 12 . Remove coolant reservoir bolts and coolant reservoir hose retaining clamp bolts. Raise and support coolant reservoir and secure to hood latch assembly. 3. Remove cooling system bleeder plug. This is a thumb-type plug on top of coolant reservoir, near coolant reservoir cap. Add approximately 4 qts. (3.7L) of 50/50 mixture of distilled water and coolant to coolant reservoir until coolant level is at FULL mark on coolant reservoir. DO NOT use plain water or alcohol based coolant. Continue to add water/coolant mixture as necessary. If cooling system does not require approximate refill capacity to maintain coolant in coolant reservoir at the FULL mark, air exists in system or system was not properly drained. See COOLING SYSTEM APPROXIMATE REFILL CAPACITY (CELICA) table. 4. If cooling system will not take additional coolant, squeeze lower radiator hose several times while using your finger to block cooling system bleeder plug opening. Continue to do this while slowly adding coolant. Start engine with coolant reservoir cap and cooling system bleeder plug removed. Ensure A/C is turned off. Operate engine until cooling fan comes on and goes off one time. Add additional coolant to coolant reservoir as necessary. 5. Install cooling system bleeder plug. Install and tighten coolant reservoir cap about 2 1/2 turns until "click" sound is heard. Increase engine speed to 3000 RPM for 5 seconds and then allow engine to idle for 5 seconds. Repeat this procedure for at least 15 minutes. Shut engine off and allow engine to completely cool. With engine completely cooled, coolant level in coolant reservoir should be between LOW and FULL marks. The next time engine operates and is at normal operating temperature, coolant level in coolant reservoir should be above the FULL mark. 6. Reinstall coolant reservoir, front fender apron seal and upper radiator support seal. Check for coolant leaks. COOLING SYSTEM APPROXIMATE REFILL CAPACITY (CELICA) Engine Qts. (L) Application 1.8L 1ZZ-FE A/T 5.9 (5.6) MT 6.0 (5.7) 1.8L 2ZZ-GE A/T 6.1 (5.8)

2002 ENGINE PERFORMANCE Removal, Overhaul & Installation - 4-Cylinder

M/T
MR2

6.2 (5.9)

1. Remove tool box and luggage compartment trim cover. See Fig. 34 . Connect air bleed hoses to heater coolant valve air drain plug and radiator air drain plug. See Fig. 35 . Suspend opposite end of air bleed hoses from the hood. Ensure air bleed hoses are not pinched or restricted. Rotate heater coolant valve air drain plug and radiator air drain plug counterclockwise to open position. 2. Slowly add a 50/50 mixture of distilled water and coolant to coolant reservoir so that coolant lever in coolant reservoir remains at least 1/2 full all the time while adding coolant to coolant reservoir. Coolant reservoir is located at driver's side rear corner of engine compartment. See Fig. 35 . DO NOT use plain water or alcohol based coolant. Approximate capacity is 11.0 qts. (10.4L). Air should bleed from air bleed hoses on heater coolant valve air drain plug and radiator air drain plug. Ensure coolant level in both air bleed hoses and coolant reservoir are at the same level. See Fig. 35 . 3. If coolant level in air bleed hoses is lower than level at coolant reservoir, air still exists in cooling system. Check for pinched or restricted air bleed hoses and repeat step 2 . When proper coolant level is obtained in air bleed hoses, close heater coolant valve air drain plug and radiator air drain plug. Install cap on coolant reservoir until "click" sound is heard and cap is in the lock position. Remove air bleed hoses. 4. Start engine and ensure air is bleeding into coolant reservoir. Warm engine to normal operating temperature. Check that coolant level in coolant reservoir is above the FULL mark. Shut engine off and allow engine to completely cool. Ensure coolant level in coolant reservoir is between LOW and FULL marks. Add coolant if necessary. Reinstall luggage compartment trim cover and tool box.

2002 ENGINE PERFORMANCE Removal, Overhaul & Installation - 4-Cylinder

Fig. 34: Locating Tool Box & Luggage Compartment Trim Cover (MR2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 ENGINE PERFORMANCE Removal, Overhaul & Installation - 4-Cylinder

Fig. 35: Installing Air Bleed Hoses & Locating Coolant Reservoir (MR2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Prius

WARNING: Read service precautions before proceeding with service procedure. See SERVICE PRECAUTIONS . 1. Slowly add a 50/50 mixture of distilled water and coolant to radiator. DO NOT use plain water or alcohol based coolant. Approximate capacity is 5.2 qts. (4.9L). 2. Install radiator cap. Start engine and allow engine to idle. Accelerate engine and then engine allow to

2002 ENGINE PERFORMANCE Removal, Overhaul & Installation - 4-Cylinder

3.

4.

5.

6. 7.

idle. Repeat this procedure several times for approximately 2 minutes. Shut engine off. Remove radiator cap and check coolant level. Coolant level should be even with rim of radiator filler neck. If coolant level decreases when pinching the upper or lower radiator hose closed several times, add coolant as necessary. Once correct coolant level is obtained, install radiator cap and go to next step. It is necessary to put transit in inspection mode so engine will run continuously. To put transit in inspection mode, perform the following steps within 60 seconds: Ensure ignition is off and then turn ignition on. Ensure transaxle is in Park and then fully depress accelerator pedal 2 times. Place transaxle in Neutral and then fully depress accelerator pedal 2 times. Place transaxle back in Park and then fully depress accelerator pedal 2 times. Check that master warning light on instrument cluster at center of instrument panel is flashing to indicate inspection mode operation. See Fig. 36 . Master warning light may also be referred to as hybrid system error warning light. Start engine and operate engine until cooling fan starts to turn with engine speed less than 2500 RPM. Shut engine off immediately after cooling fan starts to turn. Allow engine to cool until engine coolant temperature is less than 122F (50C). Remove radiator cap and recheck coolant level. If proper coolant level exists, shut engine off. Go to next step. If coolant level has dropped, add coolant and repeat steps 3 -6 . Once proper coolant level exists, shut engine off. Go to next step. Air must be bleed from heater water pump which circulates coolant through the heater core. The heater water pump may also be referred to as water pump motor (A/C). Turn ignition on with engine off. Place blower speed control dial in LO position and temperature control dial to MAX HOT position. Operate heater water pump until constant coolant flow sound exists at heater core. Ensure there is no sound of air in the coolant flow. Once constant sound of coolant flow exists through heater core, fill coolant reservoir to the maximum level.

Fig. 36: Locating Master Warning Light (Prius) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

IGNITION SYSTEMS

2002 ENGINE PERFORMANCE Removal, Overhaul & Installation - 4-Cylinder

CAMSHAFT POSITION SENSOR NOTE: On Camry, Camry Solara, Celica, Corolla, ECHO, Highlander, MR2, Prius and RAV4, camshaft position sensor may also be referred to Variable Valve Timing (VVT) sensor.

Removal & Installation (Camry & Highlander)

Camshaft position sensor is located on end of cylinder head at flywheel end of engine. See Fig. 37 . Service information is not available from manufacturer except for camshaft position sensor bolt torque specification. See TORQUE SPECIFICATIONS .
Removal & Installation (Camry Solara, Celica, Corolla, ECHO, MR2 & RAV4)

1. Note location of camshaft position sensor. See CAMSHAFT POSITION SENSOR LOCATION table. See Fig. 37 -Fig. 42 . On Celica and MR2, remove No. 2 cylinder head cover located on top of engine, above ignition coils and valve cover for access to camshaft position sensor. On MR2, remove suspension upper brace. Suspension upper brace fits between strut towers and is bolted to top of each strut tower. 2. On all models, disconnect electrical connector at camshaft position sensor. Remove bolt and camshaft position sensor with "O" ring (if equipped) from cylinder head. 3. To install, reverse removal procedure using NEW "O" ring (if equipped). Tighten camshaft position sensor bolt to specification. See TORQUE SPECIFICATIONS . On MR2, tighten suspension upper brace bolt/nut to specification. See TORQUE SPECIFICATIONS . CAMSHAFT POSITION SENSOR LOCATION Application Location Camry Solara, ECHO & RAV4 On End Of Cylinder Head At Flywheel End Of Engine Celica, Corolla & MR2 Just Above Intake Manifold On Cylinder Head, At Flywheel End Of Engine

2002 ENGINE PERFORMANCE Removal, Overhaul & Installation - 4-Cylinder

Fig. 37: Locating Typical Camshaft Position Sensor (Camry, Camry Solara & Highlander) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 ENGINE PERFORMANCE Removal, Overhaul & Installation - 4-Cylinder

Fig. 38: Locating Camshaft Position Sensor (Celica 1.8L 1ZZ-FE & Corolla) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 39: Locating Camshaft Position Sensor (Celica 1.8L 2ZZ-GE)

2002 ENGINE PERFORMANCE Removal, Overhaul & Installation - 4-Cylinder

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 40: Locating Camshaft Position Sensor (ECHO) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 ENGINE PERFORMANCE Removal, Overhaul & Installation - 4-Cylinder

Fig. 41: Locating Camshaft Position Sensor (MR2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 ENGINE PERFORMANCE Removal, Overhaul & Installation - 4-Cylinder

Fig. 42: Locating Camshaft Position Sensor (RAV4) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Removal & Installation (Prius)

WARNING: Service procedure should only be performed by authorized dealer.

Camshaft position sensor is located on end of cylinder head at flywheel end of engine and contains a Black 2-pin electrical connector with Green and Red wires. Manufacturer states that converter and inverter assembly must be removed for access to camshaft position sensor. See CONVERTER AND INVERTER ASSEMBLY in HYBRID VEHICLE CONTROL SYSTEM article.
Removal & Installation (Tacoma)

1. Camshaft position sensor is located on cylinder head, just in front of intake manifold. See Fig. 43 . 2. Remove throttle body. See THROTTLE BODY under FUEL SYSTEMS. Disconnect electrical connector at camshaft position sensor. Remove bolt and camshaft position sensor from cylinder head. 3. To install, reverse removal procedure. Tighten camshaft position sensor bolt to specification. See TORQUE SPECIFICATIONS .

2002 ENGINE PERFORMANCE Removal, Overhaul & Installation - 4-Cylinder

Fig. 43: Locating Camshaft Position Sensor (Tacoma) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. CRANKSHAFT POSITION SENSOR
Removal & Installation (Camry, Camry Solara & Highlander)

1. Crankshaft position sensor is located on side of timing chain cover. See Fig. 44 . Remove necessary components for access to crankshaft position sensor. Disconnect electrical connector for crankshaft position sensor. Remove bolt and crankshaft position sensor. 2. To install, reverse removal procedure. Tighten crankshaft position sensor bolt to specification. See TORQUE SPECIFICATIONS .

2002 ENGINE PERFORMANCE Removal, Overhaul & Installation - 4-Cylinder

Fig. 44: Locating Crankshaft Position Sensor (Camry, Camry Solara & Highlander) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Removal (Celica)

1. Crankshaft position sensor is located on front of engine, near crankshaft pulley. See Fig. 45 . Manufacturer states throttle body and intake manifold must be removed for access to crankshaft position sensor. 2. Remove throttle body. See THROTTLE BODY under FUEL SYSTEMS. Remove coolant reservoir and air cleaner case. Disconnect necessary hoses for removal of intake manifold. On 1.8L 2ZZ-GE models, remove bolts/nuts and intake manifold support from rear of intake manifold. On all models, remove bolts/nuts, intake manifold and gasket from cylinder head. 3. Disconnect electrical connector for crankshaft position sensor. Remove bolts and crankshaft position sensor.
Installation

2002 ENGINE PERFORMANCE Removal, Overhaul & Installation - 4-Cylinder

1. Install crankshaft position sensor. Install and tighten crankshaft position sensor bolts to specification. See TORQUE SPECIFICATIONS . To install remaining components, reverse removal procedure using NEW gaskets. 2. On 1.8L 2ZZ-GE models, note intake manifold bolt/nut identification before tightening intake manifold bolts/nuts to specification. See Fig. 14 . On all models, ensure gasket for throttle body is installed with protrusion area facing proper direction. See THROTTLE BODY under FUEL SYSTEMS. Tighten bolts/nuts to specification. See TORQUE SPECIFICATIONS . Fill and bleed cooling system. See COOLING SYSTEM BLEEDING under COOLING SYSTEM.

Fig. 45: Locating Typical Crankshaft Position Sensor (Celica, Corolla, MR2 & RAV4) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Removal (Corolla)

1. Crankshaft position sensor is located on front of engine, near crankshaft pulley. See Fig. 45 . Manufacturer states throttle body and intake manifold must be removed for access to crankshaft position sensor. Remove throttle body. See THROTTLE BODY under FUEL SYSTEMS. 2. Remove No. 2 cylinder head cover located on top of engine, above ignition coils and valve cover. See Fig. 15 . Disconnect necessary electrical connectors so engine wiring harness protector and engine wiring harness may be disconnected from engine wiring harness brackets. See Fig. 15 . 3. Remove bolts and disconnect engine wiring harness protector and engine wiring harness from engine wiring harness brackets. Disconnect necessary hoses for removal of intake manifold. Remove bolts from intake manifold support. Remove bolts/nuts, engine wiring harness brackets, intake manifold

2002 ENGINE PERFORMANCE Removal, Overhaul & Installation - 4-Cylinder

and gasket from cylinder head. Disconnect electrical connector for crankshaft position sensor. Remove bolts and crankshaft position sensor.
Installation

Install crankshaft position sensor. Install and tighten crankshaft position sensor bolts to specification. See TORQUE SPECIFICATIONS . To install remaining components, reverse removal procedure using NEW gaskets. Ensure gasket for throttle body is installed with protrusion area facing proper direction. See THROTTLE BODY under FUEL SYSTEMS. Tighten bolts/nuts to specification. See TORQUE SPECIFICATIONS . Fill cooling system.
Removal & Installation (ECHO)

1. Crankshaft position sensor is located on front of engine, near crankshaft pulley. See Fig. 46 . Raise and support vehicle. Remove passenger's side lower engine cover for access to crankshaft position sensor. Disconnect electrical connector for crankshaft position sensor. Remove bolt and crankshaft position sensor. 2. To install, reverse removal procedure. Tighten crankshaft position sensor bolt to specification. See TORQUE SPECIFICATIONS . Reinstall passenger's side lower engine cover.

Fig. 46: Locating Typical Crankshaft Position Sensor (ECHO & Prius) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Removal & Installation (MR2)

1. Crankshaft position sensor is located on front of engine, near crankshaft pulley. See Fig. 45 . Raise and support vehicle. Remove lower engine cover. A/C compressor must be removed for access to crankshaft position sensor. 2. Rotate automatic belt tensioner clockwise as viewed from front of engine to release tension from accessory drive belt. Remove accessory drive belt. Remove bolts and A/C compressor with hoses

2002 ENGINE PERFORMANCE Removal, Overhaul & Installation - 4-Cylinder

attached for access to crankshaft position sensor. Disconnect electrical connector for crankshaft position sensor. Remove bolt and crankshaft position sensor with "O" ring. 3. To install, reverse removal procedure using NEW "O" ring. Tighten crankshaft position sensor bolt and A/C compressor bolts to specification. See TORQUE SPECIFICATIONS .
Removal & Installation (Prius)

WARNING: Read service precautions before proceeding with service procedure. See SERVICE PRECAUTIONS . 1. Crankshaft position sensor is located on front of engine, near crankshaft pulley. See Fig. 46 . Raise and support vehicle. Remove passenger's side lower engine cover. Disconnect electrical connector for crankshaft position sensor. Remove bolt and crankshaft position sensor. 2. To install, reverse removal procedure. Tighten crankshaft position sensor bolt to specification. See TORQUE SPECIFICATIONS . Reinstall passenger's side lower engine cover.
Removal & Installation (RAV4)

1. Crankshaft position sensor is located on front of engine, near crankshaft pulley. See Fig. 45 . Raise and support vehicle. Remove lower engine cover for access to crankshaft position sensor. 2. Disconnect electrical connector for crankshaft position sensor. Remove bolt and crankshaft position sensor with "O" ring. To install, reverse removal procedure using NEW "O" ring. Tighten crankshaft position sensor bolt to specification. See TORQUE SPECIFICATIONS .
Removal & Installation (Tacoma)

1. Crankshaft position sensor is located near crankshaft pulley, just above oil pan on driver's side of engine. See Fig. 47 . Raise and support vehicle. Remove lower engine cover. 2. Disconnect negative battery cable. Disconnect electrical connectors at generator. Remove accessory drive belt, generator and generator mounting bracket. Disconnect electrical connector at crankshaft position sensor. Remove bolts and crankshaft position sensor with "O" ring. 3. To install, reverse removal procedure using NEW "O" ring. Tighten bolts to specification. See TORQUE SPECIFICATIONS .

2002 ENGINE PERFORMANCE Removal, Overhaul & Installation - 4-Cylinder

Fig. 47: Locating Crankshaft Position Sensor (Tacoma) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. IGNITION COIL
Removal & Installation (Camry, Camry Solara, Celica, Corolla, ECHO & Highlander)

1. Remove No. 2 cylinder head cover located on top of engine, above ignition coils for access to ignition coil. Disconnect electrical connector at ignition coil mounted on valve cover. 2. Note location of ignition coil for installation reference. Remove ignition coil bolt and ignition coil from valve cover. 3. To install, reverse removal procedure. Tighten ignition coil bolt to specification. See TORQUE SPECIFICATIONS .
Removal & Installation (MR2)

1. Remove suspension upper brace. Suspension upper brace fits between strut towers and is bolted to top of each strut tower. Remove No. 2 cylinder head cover located on top of engine, above ignition coils for access to ignition coil. Disconnect electrical connector at ignition coil mounted on valve cover. 2. Note location of ignition coil for installation reference. Remove ignition coil bolt, ignition coil and dust seal from valve cover. 3. To install, reverse removal procedure. Tighten ignition coil bolt and suspension upper brace bolt/nut to specification. See TORQUE SPECIFICATIONS .
Removal & Installation (Prius)

WARNING: Read service precautions before proceeding with service procedure. See SERVICE PRECAUTIONS . 1. Remove air cleaner assembly on top of engine for access to ignition coil. Disconnect electrical

2002 ENGINE PERFORMANCE Removal, Overhaul & Installation - 4-Cylinder

connector at ignition coil mounted on valve cover. 2. Note location of ignition coil for installation reference. Remove ignition coil bolt and ignition coil from valve cover. 3. To install, reverse removal procedure. Tighten ignition coil bolt to specification. See TORQUE SPECIFICATIONS .
Removal & Installation (RAV4)

1. Remove upper cap on air cleaner assembly for access to ignition coil. Disconnect electrical connector at ignition coil mounted on valve cover. 2. Note location of ignition coil for installation reference. Remove ignition coil bolt and ignition coil from valve cover. 3. To install, reverse removal procedure. Tighten ignition coil bolt to specification. See TORQUE SPECIFICATIONS .
Removal & Installation (Tacoma)

1. Remove necessary components for access to ignition coil mounted on valve cover. Disconnect electrical connector at ignition coil. Note location of ignition coil for installation reference. Remove ignition coil bolt and ignition coil from valve cover. 2. To install, reverse removal procedure. Tighten ignition coil bolt to specification. See TORQUE SPECIFICATIONS .

FUEL SYSTEMS
FUEL SYSTEM PRESSURE RELEASE WARNING: ALWAYS release fuel pressure before disconnecting any fuel injectionrelated component. DO NOT allow fuel to contact engine or electrical components.
Camry

1. Ensure ignition is off. Remove circuit opening relay from fuse/relay box. See Fig. 48 . Fuse/relay box is located at driver's side front corner of engine compartment. 2. Start engine and allow engine to idle until engine stalls. Attempt to start engine again to ensure engine will not start. Turn ignition off. Disconnect negative battery cable. Remove fuel tank cap to release any pressure from fuel tank. 3. Place suitable container under fuel line connection. Cover fuel line connection with shop towel. Slowly loosen or disconnect fuel line connection, allowing fuel pressure to be released. Once fuel pressure is released, fuel system components may be serviced. 4. Reinstall circuit opening relay and negative battery cable. Start engine and check operation of Malfunction Indicator Light (MIL) on instrument panel with engine running. MIL is displayed as engine icon on instrument panel. It may be possible that Diagnostic Trouble Code (DTC) P0171 may have been stored in Engine Control Module (ECM) and MIL may be illuminated with engine running due to the lean condition caused by operating engine with circuit opening relay removed. If MIL is illuminated, DTCs must be cleared from ECM. See CLEARING DIAGNOSTIC TROUBLE CODES under SELF-DIAGNOSTIC SYSTEM in appropriate SELF-DIAGNOSTICS article.

2002 ENGINE PERFORMANCE Removal, Overhaul & Installation - 4-Cylinder

NOTE:

It may be possible that power sun roof may not operate properly after battery was disconnected. If power sun roof does not operate properly, perform power sun roof reinitialization procedure. See appropriate POWER SUN ROOF REINITIALIZATION PROCEDURE under PROGRAMMING.

Fig. 48: Locating Circuit Opening Relay (Camry) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Camry Solara, Celica, Corolla, ECHO, Highlander, MR2, Prius, RAV4 & Tacoma

WARNING: On Prius, read service precautions before proceeding with service procedure. See SERVICE PRECAUTIONS . 1. On all models, disconnect electrical connector for fuel pump. See FUEL PUMP ELECTRICAL

2002 ENGINE PERFORMANCE Removal, Overhaul & Installation - 4-Cylinder

CONNECTOR LOCATION table. This is electrical connector for fuel pump and fuel gauge sending unit. Electric fuel pump is located in the fuel tank. FUEL PUMP ELECTRICAL CONNECTOR LOCATION Application Connector Location Camry Solara, Celica, Corolla Under Cover Plate, Below & ECHO Rear Seat Cushion Highlander Under Cover Plate, Below Driver's Side & Passenger's Side Rear Seats (1) Under Cover Plate, Below MR2 Luggage Compartment Boxes Behind The Seats Prius Under Cover Plate, Below Rear Seat Cushion RAV4 Under Cover Plate, Below Driver's Side Rear Seat Tacoma On Top Of Fuel Tank, At Fuel Pump (1) For additional information for removal of luggage compartment boxes, see FUEL PUMP . 2. Start engine and allow engine to idle until engine stalls. Turn ignition off. Disconnect negative battery cable. 3. Place suitable container under fuel line connection. Cover fuel line connection with shop towel. Slowly loosen or disconnect fuel line connection, allowing fuel pressure to be released. Once fuel pressure is released, fuel system components may be serviced. Reinstall electrical connector for fuel pump and negative battery cable. NOTE: On Celica, it may be possible that power sun roof may not operate properly after battery was disconnected. If power sun roof does not operate properly, perform power sun roof reinitialization procedure. See appropriate POWER SUN ROOF REINITIALIZATION PROCEDURE under PROGRAMMING.

FUEL FILTER
Removal & Installation (All Models)

Manufacturer does not list procedure for servicing of external fuel filters. Fuel filter(s) may be used on the fuel pump assembly. For servicing of fuel filter(s) on fuel pump assembly, see FUEL PUMP . FUEL FILTER ON FUEL PUMP
Removal & Installation (All Models)

For servicing of fuel filter(s) on fuel pump assembly, see FUEL PUMP .

2002 ENGINE PERFORMANCE Removal, Overhaul & Installation - 4-Cylinder

FUEL PUMP NOTE: When servicing fuel pump, use care to cover all fuel line fittings and connections to prevent dirt from entering fuel pump or fuel lines.

Removal (Camry)

1. Release fuel pressure. See FUEL SYSTEM PRESSURE RELEASE . 2. Remove rear seat cushion and cover plate on floor panel for access to fuel pump if not previously done. Disconnect electrical connector from top of fuel pump. This is electrical connector for fuel pump and fuel gauge sending unit. Electric fuel pump is located in fuel tank. 3. Ensure area around disconnect fitting and fuel supply line on top of fuel pump is clean. Remove retaining clip from disconnect fitting on fuel supply line at top of fuel pump. See Fig. 49 . Disconnect fuel supply line from top of fuel pump. DO NOT bend or twist fuel supply line or disconnect fitting during removal. Use care not to damage the nylon fuel supply line and disconnect fitting during removal, as there are "O" rings inside the disconnect fitting. 4. Remove fuel pump retaining plate-to-fuel tank bolts and fuel pump retaining plate. Remove fuel pump assembly and gasket from fuel tank. Use care not to damage fuel filter on bottom of fuel pump and fuel gauge sending unit when removing fuel pump.

2002 ENGINE PERFORMANCE Removal, Overhaul & Installation - 4-Cylinder

Fig. 49: Locating Retaining Clip, Disconnect Fitting, Fuel Supply Line & Fuel Pump Retaining Plate (Camry & Highlander) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Disassembly & Reassembly

1. Using screwdriver, release snap fit areas on No. 2 fuel suction support and remove No. 2 fuel suction support from bottom of fuel pump. See Fig. 50 . Remove rubber cushion from bottom of fuel pump. 2. Remove fuel pressure regulator with "O" ring. See Fig. 50 . Disconnect lead wire at fuel pump. Remove fuel pump with fuel filter from fuel filter assembly. See Fig. 50 . Using small screwdriver, remove retaining clip that holds fuel filter on bottom of fuel pump. Remove fuel filter from bottom of fuel pump.

2002 ENGINE PERFORMANCE Removal, Overhaul & Installation - 4-Cylinder

3. Using screwdriver, release snap fit areas on fuel suction plate subassembly and separate fuel suction plate subassembly from fuel filter assembly. See Fig. 50 . If necessary to remove fuel gauge sending unit, unlock fuel gauge sending unit. Slide fuel gauge sending unit downward and remove. 4. To reassemble, reverse disassembly procedure using NEW retaining clip on fuel filter and NEW "O" ring. Coat "O" ring with gasoline before installing. Ensure fuel gauge sending unit is fully locked in place by pushing fuel gauge sending unit downward.
Installation

To install, reverse removal procedure using NEW gasket. Tighten fuel pump retaining plate-to-fuel tank bolts to specification. See TORQUE SPECIFICATIONS . Ensure areas are clean before installing fuel supply line at fuel pump and retaining clip is properly installed and fuel supply line cannot be pulled from fuel pump assembly. Operate fuel pump and check for fuel leaks. See FUEL PUMP OPERATION under FUEL SYSTEMS in BASIC DIAGNOSTIC PROCEDURES - 4-CYLINDER article.

2002 ENGINE PERFORMANCE Removal, Overhaul & Installation - 4-Cylinder

Fig. 50: Exploded View Of Fuel Pump & Components (Camry) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Removal (Camry Solara)

1. Release fuel pressure. See FUEL SYSTEM PRESSURE RELEASE . 2. Remove rear seat cushion and cover plate on floor panel for access to fuel pump if not previously done. Disconnect electrical connector from top of fuel pump. This is electrical connector for fuel pump and fuel gauge sending unit. Electric fuel pump is located in the fuel tank. 3. Remove bolts and fuel pump protector cover located on fuel tank, above fuel pump. Ensure area around disconnect fitting on fuel line at fuel pump is clean. Depress both sides of retainer and pull fuel line with disconnect fitting from outlet tube on the fuel pump. See Fig. 51 . 4. Remove fuel pump retaining plate-to-fuel tank bolts. Remove fuel pump retaining plate, fuel pump and gasket from fuel tank. Use care not to damage fuel filter on bottom of fuel pump and fuel gauge sending unit when removing fuel pump.

Fig. 51: Disconnecting Fuel Line At Fuel Pump (Camry Solara) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Disassembly & Reassembly

1. Note location of fuel pump mounting bracket. See Fig. 52 . Using screwdriver, release snap fit areas on fuel pump mounting bracket and remove fuel pump mounting bracket with round fuel filter from

2002 ENGINE PERFORMANCE Removal, Overhaul & Installation - 4-Cylinder

fuel pump. See Fig. 53 . 2. Disconnect electrical connector at fuel pump. Disconnect fuel gauge sending unit wire from bottom of fuel pump mounting bracket. Using screwdriver, release snap fit areas on fuel pump in proper sequence and remove cover bracket and rubber cushion from bottom of fuel pump. See Fig. 53 . 3. Using small screwdriver, remove retaining clip that holds fuel filter on bottom of fuel pump. See Fig. 52 . Remove fuel filter from fuel pump. To reassemble, reverse disassembly procedure using NEW retaining clip on fuel filter.
Installation

1. Using NEW gasket, install fuel pump in fuel tank. Tighten fuel pump retaining plate-to-fuel tank bolts to specification. See TORQUE SPECIFICATIONS . CAUTION: DO NOT reuse old retainer when installing fuel line on outlet tube at fuel pump. Always use a NEW retainer. 2. Ensure areas are clean before installing fuel line at fuel pump. Apply light coat of engine oil on tip of outlet tube at fuel pump to allow for ease of disconnect fitting and fuel line installation. Using NEW retainer, install fuel line on outlet tube at fuel pump until "click" sound is heard. DO NOT reuse old retainer. Pull on fuel line to ensure fuel line is properly locked on the fuel pump. 3. To install remaining components, reverse removal procedure. Tighten fuel pump protector cover bolts to specification. See TORQUE SPECIFICATIONS . 4. Operate fuel pump and check for fuel leaks. See FUEL PUMP OPERATION under FUEL SYSTEMS in BASIC DIAGNOSTIC PROCEDURES - 4-CYLINDER article.

2002 ENGINE PERFORMANCE Removal, Overhaul & Installation - 4-Cylinder

Fig. 52: Exploded View Of Fuel Pump & Components (Camry Solara) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 ENGINE PERFORMANCE Removal, Overhaul & Installation - 4-Cylinder

Fig. 53: Removing Fuel Pump & Cover Bracket (Camry Solara) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Removal (Celica)

1. Release fuel pressure. See FUEL SYSTEM PRESSURE RELEASE . 2. Remove rear seat cushion and cover plate on floor panel for access to fuel pump if not previously done. Disconnect electrical connector from top of fuel pump. This is electrical connector for fuel pump and fuel gauge sending unit. Electric fuel pump is located in the fuel tank. Disconnect electrical

2002 ENGINE PERFORMANCE Removal, Overhaul & Installation - 4-Cylinder

connector at vapor pressure sensor. See Fig. 54 . 3. Ensure area around emission tube and fuel line at fuel pump is clean. Remove retaining clip from fuel line at fuel pump. See Fig. 54 . Disconnect fuel line from fuel pump. Disconnect emission tube. 4. Remove fuel pump retaining plate-to-fuel tank bolts. Remove fuel pump retaining plate, fuel pump and gasket from fuel tank. Use care not to damage fuel filter on bottom of fuel pump and fuel gauge sending unit when removing fuel pump.

Fig. 54: Locating Emission Tube, Fuel Line, Retaining Clip & Vapor Pressure Sensor (Celica) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Disassembly & Reassembly

1. Using screwdriver, pry No. 2 fuel suction support from bottom of fuel pump. See Fig. 55 . Remove rubber cushion. 2. Disconnect lead wire for fuel gauge sending unit. Press lock on main fuel filter and slide fuel gauge sending unit from main fuel filter. See Fig. 56 . Main fuel filter may also be referred to as fuel pump filter. Using screwdriver, remove No. 1 fuel suction support from main fuel filter. See Fig. 57 . Use care not to damage No. 1 fuel suction support and main fuel filter during removal. 3. Disconnect lead wire from fuel pump and No. 1 fuel suction support. Remove retaining clip and vapor pressure sensor from No. 1 fuel suction support. Remove fuel pump from main fuel filter. Remove fuel pressure regulator with "O" ring from main fuel filter. Using small screwdriver, remove retaining

2002 ENGINE PERFORMANCE Removal, Overhaul & Installation - 4-Cylinder

clip that holds fuel filter on bottom of fuel pump. Remove fuel filter from fuel pump. 4. To reassemble, reverse disassembly procedure using NEW retaining clip on fuel filter and NEW "O" ring on fuel pressure regulator. Coat "O" ring with gasoline before installing fuel pressure regulator. Install fuel gauge sending unit on main fuel filter so fuel gauge sending unit installation distance between float fulcrum and No. 1 fuel suction support is 5.91" (150.0 mm). See Fig. 58 .
Installation

1. To install, reverse removal procedure using NEW gasket. Tighten fuel pump retaining plate-to-fuel tank bolts to specification. See TORQUE SPECIFICATIONS . Ensure areas are clean before installing fuel line at fuel pump and retaining clip is properly installed and fuel line cannot be pulled from fuel pump assembly. 2. Operate fuel pump and check for fuel leaks. See FUEL PUMP OPERATION under FUEL SYSTEMS in BASIC DIAGNOSTIC PROCEDURES - 4-CYLINDER article.

2002 ENGINE PERFORMANCE Removal, Overhaul & Installation - 4-Cylinder

Fig. 55: Exploded View Of Fuel Pump & Components (Celica) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 ENGINE PERFORMANCE Removal, Overhaul & Installation - 4-Cylinder

Fig. 56: Removing Fuel Gauge Sending Unit (Celica) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 ENGINE PERFORMANCE Removal, Overhaul & Installation - 4-Cylinder

Fig. 57: Removing No. 1 Fuel Suction Support (Celica) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 58: Measuring Fuel Gauge Sending Unit Installation Distance (Celica) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 ENGINE PERFORMANCE Removal, Overhaul & Installation - 4-Cylinder

Removal (Corolla)

1. Release fuel pressure. See FUEL SYSTEM PRESSURE RELEASE . 2. Remove rear seat cushion and cover plate on floor panel for access to fuel pump if not previously done. Disconnect electrical connector from top of fuel pump. This is electrical connector for fuel pump and fuel gauge sending unit. Electric fuel pump is located in fuel tank. 3. Ensure area around fuel line at fuel pump is clean. Remove retaining clip from fuel line at fuel pump. See Fig. 59 . Disconnect fuel line from fuel pump. 4. Remove fuel pump retaining plate-to-fuel tank bolts. Remove fuel pump retaining plate, fuel pump and gasket from fuel tank. Use care not to damage fuel filter on bottom of fuel pump and fuel gauge sending unit when removing fuel pump.

Fig. 59: Removing Retaining Clip At Fuel Line (Corolla) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Disassembly & Reassembly

1. Using screwdriver, pry No. 2 fuel suction support from bottom of fuel pump. See Fig. 60 . Remove rubber cushion. Remove fuel pressure regulator with "O" ring from main fuel filter. CAUTION: Use care when removing retaining clip as not to damage the No. 1 fuel suction support.

2002 ENGINE PERFORMANCE Removal, Overhaul & Installation - 4-Cylinder

2. Using small screwdriver, remove retaining clip that holds fuel filter on bottom of fuel pump. Remove fuel filter from fuel pump. DO NOT damage No. 1 fuel suction support when removing retaining clip. 3. Using small screwdriver, pry No. 1 fuel suction support from fuel pump mounting bracket and fuel gauge sending unit. Use care not to damage No. 1 fuel suction support and fuel pump mounting bracket. Fuel pump mounting bracket may also be referred to as fuel suction plate. 4. Remove fuel filter cushion from bottom of main fuel filter. Fuel filter cushion may also be referred to as No. 2 fuel filter cushion. Remove main fuel filter with fuel pump from fuel pump mounting bracket. Disconnect electrical connector from fuel pump. Remove fuel pump from main fuel filter. 5. To reassemble, reverse disassembly procedure using NEW "O" ring on fuel pressure regulator and NEW retaining clip on fuel filter. Coat "O" ring with gasoline before installing fuel pressure regulator.
Installation

1. To install, reverse removal procedure using NEW gasket. Tighten fuel pump retaining plate-to-fuel tank bolts to specification. See TORQUE SPECIFICATIONS . Ensure areas are clean before installing fuel line at fuel pump and retaining clip is properly installed and fuel line cannot be pulled from fuel pump assembly. 2. Operate fuel pump and check for fuel leaks. See FUEL PUMP OPERATION under FUEL SYSTEMS in BASIC DIAGNOSTIC PROCEDURES - 4-CYLINDER article.

2002 ENGINE PERFORMANCE Removal, Overhaul & Installation - 4-Cylinder

Fig. 60: Exploded View Of Fuel Pump & Components (Corolla) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Removal (ECHO)

1. Release fuel pressure. See FUEL SYSTEM PRESSURE RELEASE . 2. Remove rear seat cushion and cover plate on floor panel for access to fuel pump if not previously done. Disconnect electrical connector from top of fuel pump. This is electrical connector for fuel pump and fuel gauge sending unit. Electric fuel pump is located in the fuel tank. Disconnect electrical connector at vapor pressure sensor. See Fig. 61 . 3. Ensure area around emission tube and fuel line at fuel pump is clean. Remove retaining clip from fuel

2002 ENGINE PERFORMANCE Removal, Overhaul & Installation - 4-Cylinder

line at fuel pump. See Fig. 61 . Disconnect fuel line from fuel pump. Disconnect emission tube. 4. Remove fuel pump retaining plate-to-fuel tank bolts. Remove fuel pump retaining plate, fuel pump and gasket from fuel tank. Use care not to damage fuel filter on bottom of fuel pump and fuel gauge sending unit when removing fuel pump.

Fig. 61: Locating Emission Tube, Fuel Line, Retaining Clip & Vapor Pressure Sensor (ECHO) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Disassembly & Reassembly

1. Using screwdriver, pry No. 2 fuel suction support from bottom of fuel pump. See Fig. 62 . Remove rubber cushion and fuel pressure regulator with "O" ring. 2. Disconnect electrical connector for fuel gauge sending unit. Using screwdriver, remove No. 1 fuel suction support from fuel filter. See Fig. 63 . Use care not to damage No. 1 fuel suction support during removal. Remove "O" ring from No. 1 fuel suction support. Disconnect lead wire from fuel pump. 3. Remove retaining clip and vapor pressure sensor from No. 1 fuel suction support. Remove fuel pump with "O" ring from fuel filter. Remove "O" ring from fuel pump. 4. To reassemble, reverse disassembly procedure using NEW "O" rings. Coat "O" rings with gasoline before installing.
Installation

1. To install, reverse removal procedure using NEW gasket. Tighten fuel pump retaining plate-to-fuel

2002 ENGINE PERFORMANCE Removal, Overhaul & Installation - 4-Cylinder

tank bolts to specification. See TORQUE SPECIFICATIONS . Ensure areas are clean before installing fuel line at fuel pump and retaining clip is properly installed and fuel line cannot be pulled from fuel pump assembly. 2. Operate fuel pump and check for fuel leaks. See FUEL PUMP OPERATION under FUEL SYSTEMS in BASIC DIAGNOSTIC PROCEDURES - 4-CYLINDER article.

2002 ENGINE PERFORMANCE Removal, Overhaul & Installation - 4-Cylinder

Fig. 62: Exploded View Of Fuel Pump & Components (ECHO) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 ENGINE PERFORMANCE Removal, Overhaul & Installation - 4-Cylinder

Fig. 63: Removing No. 1 Fuel Suction Support (ECHO) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Removal (Highlander)

1. Release fuel pressure. See FUEL SYSTEM PRESSURE RELEASE . 2. Remove driver's side and passenger's side rear seats and cover plate on floor panel for access to fuel pump if not previously done. Disconnect electrical connector from top of fuel pump. This is electrical connector for fuel pump and fuel gauge sending unit. Electric fuel pump is located in fuel tank. 3. Ensure area around disconnect fitting and fuel supply line on top of fuel pump is clean. Remove retaining clip from disconnect fitting on fuel supply line at top of fuel pump. See Fig. 49 . Disconnect fuel supply line from top of fuel pump. DO NOT bend or twist fuel supply line or disconnect fitting during removal. Use care not to damage the nylon fuel supply line and disconnect fitting during removal, as there are "O" rings inside the disconnect fitting. 4. Remove fuel pump retaining plate-to-fuel tank bolts and fuel pump retaining plate. Lift fuel pump assembly upward and disconnect necessary fuel line and then remove fuel pump assembly from fuel tank. Use care not to damage fuel filter on bottom of fuel pump and fuel gauge sending unit when removing fuel pump.
Disassembly & Reassembly

1. Using screwdriver, release snap fit areas on No. 2 fuel suction support and remove No. 2 fuel suction support from bottom of fuel pump. See Fig. 64 . Remove rubber cushion from bottom of fuel pump. 2. Remove fuel pressure regulator with jet pump assembly and "O" ring. See Fig. 64 . Using small screwdriver, remove retaining clip that holds fuel filter on bottom of fuel pump. Remove fuel filter from fuel pump. 3. Using screwdriver, release snap fit areas on No. 1 fuel suction support and remove No. 1 fuel suction

2002 ENGINE PERFORMANCE Removal, Overhaul & Installation - 4-Cylinder

support from fuel pump mounting bracket. See Fig. 64 . Disconnect fuel pump electrical connector from top of fuel pump. Remove fuel pump with main fuel filter. Remove fuel pump from main fuel filter. If necessary to remove fuel gauge sending unit from fuel pump mounting bracket, disengage fuel gauge sending unit. Slide fuel gauge sending unit downward and remove from fuel pump mounting bracket. 4. To reassemble, reverse disassembly procedure using NEW retaining clip on fuel filter and NEW "O" rings. Coat "O" ring with gasoline before installing. Ensure fuel gauge sending unit is fully seated in fuel pump mounting bracket.
Installation

To install, reverse removal procedure. Ensure areas are clean before installing fuel supply line at fuel pump and retaining clip is properly installed and fuel supply line cannot be pulled from fuel pump assembly. Operate fuel pump and check for fuel leaks. See FUEL PUMP OPERATION under FUEL SYSTEMS in BASIC DIAGNOSTIC PROCEDURES - 4-CYLINDER article.

2002 ENGINE PERFORMANCE Removal, Overhaul & Installation - 4-Cylinder

Fig. 64: Exploded View Of Fuel Pump & Components (Highlander) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Removal (MR2)

1. Release fuel pressure. See FUEL SYSTEM PRESSURE RELEASE . 2. Apply tape to end of screwdriver to prevent scratching interior components. Using screwdriver,

2002 ENGINE PERFORMANCE Removal, Overhaul & Installation - 4-Cylinder

remove door opening scuff plates, lower trim covers and quarter trim covers. See Fig. 4 . Remove luggage compartment lids, luggage compartment boxes and cover plate on floor panel for access to fuel pump if not previously done. Disconnect electrical connector from top of fuel pump. This is electrical connector for fuel pump and fuel gauge sending unit. Electric fuel pump is located in fuel tank. 3. Remove bolts and fuel pump protector cover located on fuel tank, above fuel pump. Disconnect electrical connector at vapor pressure sensor. See Fig. 65 . Ensure area around emission tube and fuel line at fuel pump is clean. Remove retaining clip from fuel line at fuel pump. See Fig. 65 . Disconnect fuel line from fuel pump. Disconnect emission tube. 4. Remove fuel pump retaining plate-to-fuel tank bolts and fuel pump retaining plate. Remove fuel pump assembly with gasket from fuel tank. Use care not to damage fuel filter on bottom of fuel pump and fuel gauge sending unit when removing fuel pump.

Fig. 65: Locating Vapor Pressure Sensor, Retaining Clip, Disconnect Fitting, Fuel Line & Fuel Pump Retaining Plate (MR2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Disassembly & Reassembly

1. Using screwdriver, pry No. 2 fuel suction support from bottom of fuel pump. See Fig. 66 . Remove rubber cushion from bottom of fuel pump. 2. Disconnect lead wire from bottom of No. 1 fuel suction support. No. 1 fuel suction support may also

2002 ENGINE PERFORMANCE Removal, Overhaul & Installation - 4-Cylinder

be referred to as fuel suction plate. Using screwdriver, release snap fit areas on No. 1 fuel suction support and remove No. 1 fuel suction support from main fuel filter. See Fig. 67 . Use care not to damage No. 1 fuel suction support and main fuel filter. Main fuel filter may also be referred to as fuel filter assembly. 3. Disconnect electrical connector for fuel pump from bottom of No. 1 fuel suction support. Remove fuel pump from main fuel filter. See Fig. 66 . Using small screwdriver, remove retaining clip that holds fuel filter on bottom of fuel pump. Remove fuel filter from fuel pump. Remove fuel pressure regulator with "O" ring from top of main fuel filter. See Fig. 66 . Remove "O" ring from fuel pressure regulator. 4. To reassemble, reverse disassembly procedure using NEW retaining clip on fuel filter and NEW "O" ring. Coat "O" ring with gasoline before installing fuel pressure regulator.
Installation

1. To install, reverse removal procedure using NEW gasket. Ensure fuel pump assembly is positioned so reference mark aligns with specified bolt hole and emission tube fitting is pointing toward front of vehicle. See Fig. 68 . 2. Tighten fuel pump retaining plate-to-fuel tank bolts and fuel pump protector cover bolts to specification. See TORQUE SPECIFICATIONS . Ensure areas are clean before installing fuel line at fuel pump and retaining clip is properly installed and fuel line cannot be pulled from fuel pump assembly. Operate fuel pump and check for fuel leaks. See FUEL PUMP OPERATION under FUEL SYSTEMS in BASIC DIAGNOSTIC PROCEDURES - 4-CYLINDER article. Reinstall luggage compartment components.

2002 ENGINE PERFORMANCE Removal, Overhaul & Installation - 4-Cylinder

Fig. 66: Exploded View Of Fuel Pump & Components (MR2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 ENGINE PERFORMANCE Removal, Overhaul & Installation - 4-Cylinder

Fig. 67: Removing No. 1 Fuel Suction Support (MR2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 ENGINE PERFORMANCE Removal, Overhaul & Installation - 4-Cylinder

Fig. 68: Installing Fuel Pump Assembly (MR2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Removal (Prius)

WARNING: Read service precautions before proceeding with service procedure. See SERVICE PRECAUTIONS . 1. It may be necessary to replace fuel pump and fuel tank as an assembly. Consult local parts department for parts availability. To remove fuel tank, release fuel pressure. See FUEL SYSTEM PRESSURE RELEASE . 2. Remove rear seat cushion and cover plate on floor panel for access to fuel pump if not previously done. Disconnect electrical connector from top of fuel pump. This is electrical connector for fuel pump and fuel gauge sending unit. Electric fuel pump is located in the fuel tank. 3. Raise and support vehicle. Remove exhaust pipe assembly and tailpipe for access to fuel tank. Drain gasoline from fuel tank into approved container. Disconnect fuel filler tube and any remaining hoses for fuel tank removal. Support fuel tank with transmission jack. Remove fuel tank retaining bolts and fuel tank.
Installation

To install, reverse removal procedure using NEW gasket on exhaust pipe at exhaust manifold. Tighten fuel

2002 ENGINE PERFORMANCE Removal, Overhaul & Installation - 4-Cylinder

tank retaining bolts and exhaust pipe-to-exhaust manifold bolts to specification. See TORQUE SPECIFICATIONS . Operate fuel pump and check for fuel leaks. See FUEL PUMP OPERATION under FUEL SYSTEMS in BASIC DIAGNOSTIC PROCEDURES - 4-CYLINDER article.
Removal (RAV4)

1. Release fuel pressure. See FUEL SYSTEM PRESSURE RELEASE . Remove driver's side rear seat and cover plate on floor panel for access to electrical connector for fuel pump if not previously done. 2. Disconnect electrical connector from top of fuel pump. This is electrical connector for fuel pump and fuel gauge sending unit. Electric fuel pump is located in fuel tank. Disconnect electrical connector at vapor pressure sensor. See Fig. 69 . 3. Ensure area around fuel line at fuel pump is clean. Remove retaining clip from fuel line at fuel pump. See Fig. 69 . Disconnect fuel line from fuel pump. Remove fuel pump retaining plate-to-fuel tank bolts and fuel pump retaining plate. 4. Lift fuel pump assembly upward and disconnect fuel line from fuel pressure regulator and then remove fuel pump assembly with gasket from fuel tank. Use care not to damage fuel filter on bottom of fuel pump and fuel gauge sending unit when removing fuel pump.

Fig. 69: Locating Retaining Clip, Fuel Line, Fuel Pump Retaining Plate & Vapor Pressure Sensor (RAV4) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Disassembly & Reassembly

2002 ENGINE PERFORMANCE Removal, Overhaul & Installation - 4-Cylinder

1. Using screwdriver, pry No. 2 fuel suction support from bottom of fuel pump. See Fig. 70 . Remove rubber cushion from bottom of fuel pump. 2. Disconnect lead wire from bottom of No. 1 fuel suction support. No. 1 fuel suction support may also be referred to as fuel suction plate. Using screwdriver, release snap fit areas on No. 1 fuel suction support and remove No. 1 fuel suction support from main fuel filter. See Fig. 71 . Use care not to damage No. 1 fuel suction support and main fuel filter. Main fuel filter may also be referred to as fuel filter assembly. 3. Disconnect electrical connector for fuel pump from bottom of No. 1 fuel suction support. Remove fuel pump from main fuel filter. See Fig. 70 . Using small screwdriver, remove retaining clip that holds fuel filter on bottom of fuel pump. Remove fuel filter from fuel pump. Remove fuel pressure regulator with "O" ring from top of main fuel filter. See Fig. 70 . Remove "O" ring from fuel pressure regulator. 4. To reassemble, reverse disassembly procedure using NEW retaining clip on fuel filter and NEW "O" ring. Coat "O" ring with gasoline before installing fuel pressure regulator.
Installation

1. To install, reverse removal procedure using NEW gasket. Ensure fuel pump assembly is positioned so reference mark aligns with specified bolt hole and fuel pump is properly positioned in fuel tank. See Fig. 72 . 2. Tighten fuel pump retaining plate-to-fuel tank bolts to specification. See TORQUE SPECIFICATIONS . Ensure areas are clean before installing fuel line at fuel pump and retaining clip is properly installed and fuel line cannot be pulled from fuel pump assembly. Operate fuel pump and check for fuel leaks. See FUEL PUMP OPERATION under FUEL SYSTEMS in BASIC DIAGNOSTIC PROCEDURES - 4-CYLINDER article.

2002 ENGINE PERFORMANCE Removal, Overhaul & Installation - 4-Cylinder

Fig. 70: Exploded View Of Fuel Pump & Components (RAV4) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 ENGINE PERFORMANCE Removal, Overhaul & Installation - 4-Cylinder

Fig. 71: Removing No. 1 Fuel Suction Support (RAV4) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 ENGINE PERFORMANCE Removal, Overhaul & Installation - 4-Cylinder

Fig. 72: Installing Fuel Pump Assembly (RAV4) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Removal (Tacoma)

1. Release fuel pressure. See FUEL SYSTEM PRESSURE RELEASE . 2. Electric fuel pump is located in fuel tank. Fuel tank must be removed for servicing of fuel pump. Raise and support vehicle. Remove necessary covers for access to fuel tank. Drain gasoline from fuel tank into approved container. 3. Disconnect fuel filler tube and any remaining hoses for fuel tank removal. Support fuel tank with transmission jack. Remove fuel tank straps. Slightly lower fuel tank for access to fuel supply and fuel return lines at the fuel pump. 4. Disconnect electrical connector from top of fuel pump. This is electrical connector for fuel pump and fuel gauge sending unit. Disconnect electrical connector from vapor pressure sensor. See Fig. 73 . 5. Ensure area around fuel supply and fuel return lines on top of fuel pump is clean. Disconnect fuel supply and fuel return lines from top of fuel pump. Remove fuel tank. Remove fuel pump mounting bracket-to-fuel tank bolts. Remove fuel pump assembly and gasket from fuel tank. Use care not to damage fuel filter on bottom of fuel pump and fuel gauge sending unit when removing fuel pump.
Disassembly & Reassembly

1. Disconnect electrical connector on lead wire from the fuel pump. See Fig. 73 . Pull bottom of fuel pump from fuel pump mounting bracket. 2. Disconnect fuel hose at top of fuel pump. Remove fuel pump with rubber cushion from fuel pump

2002 ENGINE PERFORMANCE Removal, Overhaul & Installation - 4-Cylinder

mounting bracket. Remove rubber cushion from bottom of fuel pump. Using small screwdriver, remove retaining clip that holds fuel filter on bottom of fuel pump. Remove fuel filter from fuel pump. To reassemble, reverse disassembly procedure using NEW retaining clip on fuel filter.
Installation

1. To install, reverse removal procedure using NEW gasket. Tighten fuel pump mounting bracket-to-fuel tank bolts to specification. See TORQUE SPECIFICATIONS . 2. Operate fuel pump and check for fuel leaks before installing fuel tank. See FUEL PUMP OPERATION under FUEL SYSTEMS in BASIC DIAGNOSTIC PROCEDURES - 4-CYLINDER article. Before installing fuel tank, ensure insulator cushions are installed in proper areas on top of fuel tank. See Fig. 74 .

2002 ENGINE PERFORMANCE Removal, Overhaul & Installation - 4-Cylinder

Fig. 73: Exploded View Of Fuel Pump & Components (Tacoma) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 ENGINE PERFORMANCE Removal, Overhaul & Installation - 4-Cylinder

Fig. 74: Locating Insulator Cushions On Fuel Tank (Tacoma) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. FUEL PRESSURE REGULATOR
Removal & Installation (Camry)

1. Fuel pressure regulator is located on fuel pump assembly in the fuel tank. See Fig. 50 . Remove fuel pump from fuel tank. See FUEL PUMP . 2. Using screwdriver, release snap fit areas on No. 2 fuel suction support and remove No. 2 fuel suction support from bottom of fuel pump. See Fig. 50 . Remove rubber cushion from bottom of fuel pump. 3. Remove fuel pressure regulator with "O" ring. See Fig. 50 . Remove "O" ring from fuel pressure regulator. 4. To install, reverse removal procedure using NEW "O" ring. Coat "O" ring with gasoline before installing fuel pressure regulator. Reinstall fuel pump.
Removal (Camry Solara)

1. Fuel pressure regulator is located on fuel pump assembly in the fuel tank. See Fig. 75 . Remove fuel pump from fuel tank. See FUEL PUMP . 2. Remove round fuel filter retaining screw and round fuel filter with "O" ring from fuel pressure regulator. See Fig. 75 . 3. Remove fuel pressure regulator retaining screw. Remove fuel pressure regulator with "O" ring from fuel pump mounting bracket. Remove "O" ring from fuel pressure regulator.
Installation

To install, reverse removal procedure using NEW "O" rings. Coat "O" ring with gasoline before installing fuel pressure regulator and round fuel filter. Tighten fuel pressure regulator retaining screw and round fuel filter retaining screw to specification. See TORQUE SPECIFICATIONS . Reinstall fuel pump.

2002 ENGINE PERFORMANCE Removal, Overhaul & Installation - 4-Cylinder

Fig. 75: Locating Fuel Pressure Regulator (Camry Solara) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Removal & Installation (Celica)

1. Fuel pressure regulator is located on fuel pump assembly in the fuel tank. See Fig. 55 . Remove fuel pump from fuel tank. See FUEL PUMP . 2. Using screwdriver, remove No. 1 fuel suction support from main fuel filter. See Fig. 57 . Use care not to damage No. 1 fuel suction support during removal. Disconnect lead wire from fuel pump and No. 1 fuel suction support. Remove fuel pressure regulator with "O" ring from main fuel filter.

2002 ENGINE PERFORMANCE Removal, Overhaul & Installation - 4-Cylinder

3. To install, reverse removal procedure using NEW "O" ring on fuel pressure regulator. Coat "O" ring with gasoline before installing fuel pressure regulator. Reinstall fuel pump.
Removal & Installation (Corolla & ECHO)

1. Fuel pressure regulator is located on fuel pump assembly in the fuel tank. See Fig. 60 and Fig. 62 . Remove fuel pump from fuel tank. See FUEL PUMP . 2. Using screwdriver, pry No. 2 fuel suction support from bottom of fuel pump. See Fig. 60 and Fig. 62 . Remove rubber cushion. Remove fuel pressure regulator with "O" ring. 3. To install, reverse removal procedure using NEW "O" ring on fuel pressure regulator. Coat "O" ring with gasoline before installing fuel pressure regulator. Reinstall fuel pump.
Removal & Installation (Highlander)

1. Fuel pressure regulator contains the jet pump assembly and is located on fuel pump assembly in the fuel tank. See Fig. 64 . Remove fuel pump from fuel tank. See FUEL PUMP . 2. Using screwdriver, release snap fit areas on No. 2 fuel suction support and remove No. 2 fuel suction support from bottom of fuel pump. See Fig. 64 . Remove rubber cushion from bottom of fuel pump. Remove fuel pressure regulator with jet pump assembly and "O" ring. Remove "O" ring from fuel pressure regulator with jet pump assembly. 3. To install, reverse removal procedure using NEW "O" ring on fuel pressure regulator with jet pump assembly. Coat "O" ring with gasoline before installing fuel pressure regulator with jet pump assembly. Reinstall fuel pump.
Removal & Installation (MR2)

1. Fuel pressure regulator is located on fuel pump assembly in the fuel tank. See Fig. 66 . Remove fuel pump from fuel tank. See FUEL PUMP . 2. Disconnect lead wire from bottom of No. 1 fuel suction support. Using screwdriver, release snap fit areas on No. 1 fuel suction support and remove No. 1 fuel suction support from main fuel filter. See Fig. 67 . Use care not to damage No. 1 fuel suction support and main fuel filter. 3. Disconnect electrical connector for fuel pump from bottom of No. 1 fuel suction support. Remove fuel pressure regulator with "O" ring from top of main fuel filter. See Fig. 66 . Remove "O" ring from fuel pressure regulator. 4. To install, reverse removal procedure using NEW "O" ring on fuel pressure regulator. Coat "O" ring with gasoline before installing fuel pressure regulator. Reinstall fuel pump.
Removal & Installation (Prius)

WARNING: Read service precautions before proceeding with service procedure. See SERVICE PRECAUTIONS . Fuel pressure regulator is located on fuel pump assembly in the fuel tank. Manufacturer does not provide information for servicing of fuel pressure regulator. It may be necessary to replace fuel pressure regulator along with fuel pump and fuel tank as an assembly. Consult local parts department for parts availability. For servicing of fuel pump and fuel tank as an assembly, see FUEL PUMP .
Removal & Installation (RAV4)

2002 ENGINE PERFORMANCE Removal, Overhaul & Installation - 4-Cylinder

1. Fuel pressure regulator is located on fuel pump assembly in the fuel tank. See Fig. 70 . Remove fuel pump from fuel tank. See FUEL PUMP . 2. Disconnect lead wire from bottom of No. 1 fuel suction support. Using screwdriver, release snap fit areas on No. 1 fuel suction support and remove No. 1 fuel suction support from main fuel filter. See Fig. 71 . Use care not to damage No. 1 fuel suction support and main fuel filter. 3. Disconnect electrical connector for fuel pump from bottom of No. 1 fuel suction support. Disconnect tube on fuel pressure regulator from clamp. Remove fuel pressure regulator with "O" ring from top of main fuel filter. See Fig. 70 . Remove "O" ring from fuel pressure regulator. 4. To install, reverse removal procedure using NEW "O" ring on fuel pressure regulator. Coat "O" ring with gasoline before installing fuel pressure regulator. Reinstall fuel pump.
Removal (Tacoma)

1. Release fuel pressure. See FUEL SYSTEM PRESSURE RELEASE . Disconnect air hose and fuel return hose from fuel pressure regulator. Fuel pressure regulator is located on end of fuel rail at front of engine. 2. Remove bolts and fuel pressure regulator with "O" ring from fuel rail. Remove "O" ring from fuel pressure regulator.
Installation

1. To install, reverse removal procedure using NEW "O" ring. Coat "O" ring with gasoline before installing fuel pressure regulator in fuel rail. 2. Tighten fuel pressure regulator bolts to specification. See TORQUE SPECIFICATIONS . Operate fuel pump and check for fuel leaks. See FUEL PUMP OPERATION under FUEL SYSTEMS in BASIC DIAGNOSTIC PROCEDURES - 4-CYLINDER article. FUEL RAILS & FUEL INJECTORS
Removal (Camry)

1. Release fuel pressure. See FUEL SYSTEM PRESSURE RELEASE . Remove upper cap on air cleaner assembly with air cleaner hose. Remove No. 2 cylinder head cover located on top of engine, above ignition coils and valve cover. See Fig. 76 . 2. Remove fuel pipe clamp from end of fuel pipe at fuel pipe fitting. See Fig. 77 . Fuel pipe goes from end of fuel rail to fuel pipe fitting. Ensure area around fuel pipe and disconnect fitting is clean. CAUTION: Use care when disconnecting fuel pipe, as some residual fuel pressure may still exist in the fuel system. 3. Depress both tabs and pull fuel pipe with disconnect fitting from fuel pipe fitting. See Fig. 77 . Remove ventilation hose No. 2. See Fig. 76 . Remove engine wiring harness for access to fuel rail and fuel injectors. Note location of electrical connectors on fuel injectors for installation reference. Disconnect electrical connectors at fuel injectors. CAUTION: When removing fuel rail, use care not to allow fuel injectors to fall from fuel rail.

2002 ENGINE PERFORMANCE Removal, Overhaul & Installation - 4-Cylinder

4. Remove fuel rail-to-cylinder head bolts. Remove fuel rail with fuel injectors as an assembly. Remove the 2 spacers from cylinder head. Remove fuel injectors from fuel rail. Remove "O" ring and grommet from fuel injector. Grommet may also be referred to as an insulator.
Installation

1. To install, reverse removal procedure using NEW grommets and "O" rings. Coat "O" ring with gasoline before installing "O" ring on fuel injector. 2. Coat fuel rail "O" ring contact area with gasoline before installing fuel injector on fuel rail. Use twisting motion when installing fuel injector on fuel rail. Ensure electrical connector on each fuel injector is facing downward, toward intake manifold and the 2 spacers are installed on cylinder head before installing fuel rail. 3. Install fuel rail with fuel injectors on cylinder head with fuel rail-to-cylinder head bolts loosely installed. Ensure fuel injectors rotate smoothly. If fuel injectors do not rotate smoothly, check for improper "O" ring installation and replace "O" ring on fuel injector. 4. Ensure electrical connector on each fuel injector is facing downward, toward intake manifold. Tighten fuel rail-to-cylinder head bolts to specification. See TORQUE SPECIFICATIONS . To install remaining components, reverse removal procedure. Install fuel pipe on fuel pipe fitting. Pull on fuel pipe to ensure fuel pipe is properly locked on fuel pipe fitting. Reinstall fuel pipe clamp. Operate fuel pump and check for fuel leaks. See FUEL PUMP OPERATION under FUEL SYSTEMS in BASIC DIAGNOSTIC PROCEDURES - 4-CYLINDER article.

2002 ENGINE PERFORMANCE Removal, Overhaul & Installation - 4-Cylinder

Fig. 76: Exploded View Of Fuel Rail & Components (Camry & Camry Solara) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 ENGINE PERFORMANCE Removal, Overhaul & Installation - 4-Cylinder

Fig. 77: Locating Fuel Pipe Clamp & Disconnecting Fuel Pipe From Fuel Pipe Fitting (Camry) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Removal (Camry Solara)

2002 ENGINE PERFORMANCE Removal, Overhaul & Installation - 4-Cylinder

1. Release fuel pressure. See FUEL SYSTEM PRESSURE RELEASE . Remove No. 2 cylinder head cover located on top of engine, above ignition coils and valve cover. See Fig. 76 . 2. Remove ventilation hose No. 2. See Fig. 76 . Ventilation hose No. 2 may also be referred to as PCV hose. Remove engine wiring harness for access to fuel rail and fuel injectors. Note location of electrical connectors on fuel injectors for installation reference. Disconnect electrical connectors at fuel injectors. CAUTION: When removing fuel rail, use care not to allow fuel injectors to fall from fuel rail. 3. Remove fuel rail-to-cylinder head bolts. Remove fuel rail with fuel injectors as an assembly. Remove the 2 spacers from cylinder head. Remove fuel injectors from fuel rail. Remove "O" ring and grommet from fuel injector.
Installation

1. To install, reverse removal procedure using NEW grommets and "O" rings. Coat "O" ring with gasoline before installing "O" ring on fuel injector. 2. Coat fuel rail "O" ring contact area with gasoline before installing fuel injector on fuel rail. Use twisting motion when installing fuel injector on fuel rail. Ensure electrical connector on each fuel injector is facing downward, toward intake manifold and the 2 spacers are installed on cylinder head before installing fuel rail. Coat grommet contact surfaces with gasoline before installing fuel rail with fuel injectors. 3. Install fuel rail with fuel injectors on cylinder head with fuel rail-to-cylinder head bolts loosely installed. Ensure fuel injectors rotate smoothly. If fuel injectors do not rotate smoothly, check for improper "O" ring installation and replace "O" ring on fuel injector. 4. Ensure electrical connector on each fuel injector is facing downward, toward intake manifold. Tighten fuel rail-to-cylinder head bolts to specification. See TORQUE SPECIFICATIONS . To install remaining components, reverse removal procedure. Operate fuel pump and check for fuel leaks. See FUEL PUMP OPERATION under FUEL SYSTEMS in BASIC DIAGNOSTIC PROCEDURES 4-CYLINDER article.
Removal (Celica & Corolla)

1. Release fuel pressure. See FUEL SYSTEM PRESSURE RELEASE . Remove No. 2 cylinder head cover located on top of engine, above ignition coils and valve cover. See Fig. 78 and Fig. 79 . 2. Remove fuel pipe clamp from end of fuel pipe at end of fuel rail. Perform STEP 1 in illustration. See Fig. 80 and Fig. 81 . Ensure area around fuel pipe and disconnect fitting is clean. CAUTION: Use care when disconnecting fuel pipe, as some residual fuel pressure may still exist in the fuel system. 3. Depress both sides of retainer and pull fuel pipe with disconnect fitting from fuel pipe fitting. Perform STEP 2 in illustration. See Fig. 80 and Fig. 81 . Note location of electrical connectors on fuel injectors for installation reference. Disconnect electrical connectors at fuel injectors. CAUTION: When removing fuel rail, use care not to allow fuel injectors to fall from fuel rail.

2002 ENGINE PERFORMANCE Removal, Overhaul & Installation - 4-Cylinder

4. Remove bolt from fuel pipe clamp at the cylinder head. See Fig. 78 and Fig. 79 . Remove fuel rail-tocylinder head bolts. Remove fuel rail with fuel injectors as an assembly. Remove the 2 spacers from cylinder head. Remove fuel injectors from fuel rail. Remove "O" ring and grommet from fuel injector.
Installation

1. To install, reverse removal procedure using NEW grommets and "O" rings. Coat "O" ring with gasoline before installing "O" ring on fuel injector. 2. Coat fuel rail "O" ring contact area with gasoline before installing fuel injector on fuel rail. Use twisting motion when installing fuel injector on fuel rail. Ensure electrical connector on each fuel injector is facing toward valve cover and the 2 spacers are installed on cylinder head before installing fuel rail. Coat grommet contact surfaces with gasoline before installing fuel rail with fuel injectors. 3. Install fuel rail with fuel injectors on cylinder head with fuel rail-to-cylinder head bolts loosely installed. Ensure fuel injectors rotate smoothly. If fuel injectors do not rotate smoothly, check for improper "O" ring installation and replace "O" ring on fuel injector. 4. Ensure electrical connector on each fuel injector is facing toward valve cover. Tighten fuel rail-tocylinder head bolts and fuel pipe clamp-to-cylinder head bolt to specification. See TORQUE SPECIFICATIONS . Install No. 2 cylinder head cover. CAUTION: DO NOT reuse old retainer when installing fuel pipe on fuel pipe fitting. Always use a NEW retainer. 5. Apply light coat of engine oil on tip of fuel pipe fitting to allow for ease of disconnect fitting and fuel pipe installation. Using NEW retainer, install fuel pipe on fuel pipe fitting until "click" sound is heard. DO NOT reuse old retainer. Pull on fuel pipe to ensure fuel pipe is properly locked on fuel pipe fitting. 6. Reinstall fuel pipe clamp. Operate fuel pump and check for fuel leaks. See FUEL PUMP OPERATION under FUEL SYSTEMS in BASIC DIAGNOSTIC PROCEDURES - 4-CYLINDER article.

2002 ENGINE PERFORMANCE Removal, Overhaul & Installation - 4-Cylinder

Fig. 78: Exploded View Of Fuel Rail & Components (Celica) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 ENGINE PERFORMANCE Removal, Overhaul & Installation - 4-Cylinder

Fig. 79: Exploded View Of Fuel Rail & Components (Corolla) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 ENGINE PERFORMANCE Removal, Overhaul & Installation - 4-Cylinder

Fig. 80: Disconnecting Fuel Pipe From Fuel Pipe Fitting (Celica) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 ENGINE PERFORMANCE Removal, Overhaul & Installation - 4-Cylinder

Fig. 81: Disconnecting Fuel Pipe From Fuel Pipe Fitting (Corolla) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Removal (ECHO)

1. Release fuel pressure. See FUEL SYSTEM PRESSURE RELEASE . Remove No. 2 cylinder head cover located on top of engine, above ignition coils and valve cover, ignition coils, valve cover and gasket. See Fig. 82 . 2. Remove fuel pipe clamp from end of fuel pipe at end of fuel rail. Perform STEP 1 in illustration. See Fig. 83 . Ensure area around fuel pipe and disconnect fitting is clean. CAUTION: Use care when disconnecting fuel pipe, as some residual fuel

2002 ENGINE PERFORMANCE Removal, Overhaul & Installation - 4-Cylinder

pressure may still exist in the fuel system. 3. Depress both sides of retainer and pull fuel pipe with disconnect fitting from fuel pipe fitting. Perform STEP 2 in illustration. See Fig. 83 . Note location of electrical connectors on fuel injectors for installation reference. Disconnect electrical connectors at fuel injectors. CAUTION: When removing fuel rail, use care not to allow fuel injectors to fall from fuel rail. 4. Remove bolt from fuel pipe clamp at the cylinder head. See Fig. 82 . Remove fuel rail-to-cylinder head bolts. Remove fuel rail with fuel injectors as an assembly. Remove the 2 spacers from cylinder head. Remove fuel injectors from fuel rail. Remove "O" ring and grommet from fuel injector.
Installation

1. To install, reverse removal procedure using NEW grommets and "O" rings. Coat "O" ring with gasoline before installing "O" ring on fuel injector. 2. Coat fuel rail "O" ring contact area with gasoline before installing fuel injector on fuel rail. Use twisting motion when installing fuel injector on fuel rail. Ensure electrical connector on each fuel injector is facing toward valve cover and the 2 spacers are installed on cylinder head before installing fuel rail. Coat grommet contact surfaces with gasoline before installing fuel rail with fuel injectors. 3. Install fuel rail with fuel injectors on cylinder head with fuel rail-to-cylinder head bolts loosely installed. Ensure fuel injectors rotate smoothly. If fuel injectors do not rotate smoothly, check for improper "O" ring installation and replace "O" ring on fuel injector. 4. Ensure electrical connector on each fuel injector is facing toward valve cover. Tighten fuel rail-tocylinder head bolts and fuel pipe clamp-to-cylinder head bolt to specification. See TORQUE SPECIFICATIONS . 5. Apply sealant at specified areas on cylinder head before installing gasket and valve cover. See Fig. 84 . Using NEW seal washers, install valve cover bolts/nuts. Tighten valve cover bolts/nuts to specification in sequence. See TORQUE SPECIFICATIONS . See Fig. 85 . Install ignition coils and tighten ignition coil bolts to specification. See TORQUE SPECIFICATIONS . Install No. 2 cylinder head cover. CAUTION: DO NOT reuse old retainer when installing fuel pipe on fuel pipe fitting. Always use a NEW retainer. 6. Apply light coat of engine oil on tip of fuel pipe fitting to allow for ease of disconnect fitting and fuel pipe installation. Using NEW retainer, install fuel pipe on fuel pipe fitting until "click" sound is heard. DO NOT reuse old retainer. Pull on fuel pipe to ensure fuel pipe is properly locked on fuel pipe fitting. 7. Reinstall fuel pipe clamp. Operate fuel pump and check for fuel leaks. See FUEL PUMP OPERATION under FUEL SYSTEMS in BASIC DIAGNOSTIC PROCEDURES - 4-CYLINDER article.

2002 ENGINE PERFORMANCE Removal, Overhaul & Installation - 4-Cylinder

Fig. 82: Exploded View Of Fuel Rail & Components (ECHO) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 ENGINE PERFORMANCE Removal, Overhaul & Installation - 4-Cylinder

Fig. 83: Disconnecting Fuel Pipe From Fuel Pipe Fitting (ECHO) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 ENGINE PERFORMANCE Removal, Overhaul & Installation - 4-Cylinder

Fig. 84: Identifying Valve Cover Sealant Application Areas (ECHO & Prius) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 ENGINE PERFORMANCE Removal, Overhaul & Installation - 4-Cylinder

Fig. 85: Valve Cover Bolt/Nut Tightening Sequence (ECHO & Prius) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Removal (Highlander)

1. Release fuel pressure. See FUEL SYSTEM PRESSURE RELEASE . Remove upper cap on air cleaner assembly with air cleaner hose. Remove fuel pipe clamp from end of fuel pipe at fuel pipe fitting. See Fig. 86 . CAUTION: Use care when disconnecting fuel pipe, as some residual fuel pressure may still exist in the fuel system. 2. Ensure area around fuel pipe and disconnect fitting is clean. Depress both tabs and pull fuel pipe with disconnect fitting from fuel pipe fitting. See Fig. 86 . 3. Note location of electrical connectors on fuel injectors for installation reference. Disconnect electrical connectors at fuel injectors. Remove clamps and engine wiring harness for access to fuel rail. CAUTION: When removing fuel rail, use care not to allow fuel injectors to fall from fuel rail. 4. Remove fuel rail-to-cylinder head bolts. Remove fuel rail with fuel injectors as an assembly. Remove the 2 spacers from cylinder head. Remove fuel injectors from fuel rail. Remove "O" ring and insulator from fuel injector.

2002 ENGINE PERFORMANCE Removal, Overhaul & Installation - 4-Cylinder

Installation

1. To install, reverse removal procedure using NEW insulators and "O" rings. Coat "O" ring with gasoline before installing "O" ring on fuel injector. 2. Coat fuel rail "O" ring contact area with gasoline before installing fuel injector on fuel rail. Use twisting motion when installing fuel injector on fuel rail. Ensure electrical connector on each fuel injector is facing downward, toward intake manifold and the 2 spacers are installed on cylinder head before installing fuel rail. 3. Install fuel rail with fuel injectors on cylinder head with fuel rail-to-cylinder head bolts loosely installed. Ensure fuel injectors rotate smoothly. If fuel injectors do not rotate smoothly, check for improper "O" ring installation and replace "O" ring on fuel injector. 4. Ensure electrical connector on each fuel injector is facing downward, toward intake manifold. Tighten fuel rail-to-cylinder head bolts to specification. See TORQUE SPECIFICATIONS . Install fuel pipe on fuel pipe fitting. Pull on fuel pipe to ensure fuel pipe is properly locked on fuel pipe fitting. Reinstall fuel pipe clamp. Operate fuel pump and check for fuel leaks. See FUEL PUMP OPERATION under FUEL SYSTEMS in BASIC DIAGNOSTIC PROCEDURES - 4-CYLINDER article.

2002 ENGINE PERFORMANCE Removal, Overhaul & Installation - 4-Cylinder

Fig. 86: Exploded View Of Fuel Rail & Components (Highlander) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Removal (MR2)

1. Release fuel pressure. See FUEL SYSTEM PRESSURE RELEASE . Remove suspension upper brace and No. 2 cylinder head cover located on top of engine, above ignition coils and valve cover. See Fig. 87 . 2. Remove PCV hose and engine wiring harness for access to fuel rail. Note location of electrical connectors on fuel injectors for installation reference. Disconnect electrical connectors at fuel injectors. CAUTION: When removing fuel rail, use care not to allow fuel injectors to fall

2002 ENGINE PERFORMANCE Removal, Overhaul & Installation - 4-Cylinder

from fuel rail. 3. Remove fuel rail-to-cylinder head bolts. Remove fuel rail with fuel injectors as an assembly. Remove the 2 spacers and 4 grommets from cylinder head. Remove fuel injectors from fuel rail. Remove "O" ring from fuel injector.
Installation

1. To install, reverse removal procedure using NEW grommets and "O" rings. Coat "O" ring with gasoline before installing "O" ring on fuel injector. 2. Coat fuel rail "O" ring contact area with gasoline before installing fuel injector on fuel rail. Use twisting motion when installing fuel injector on fuel rail. Ensure electrical connector on each fuel injector is facing toward valve cover and the 2 spacers and 4 grommets are installed on cylinder head before installing fuel rail. 3. Install fuel rail with fuel injectors on cylinder head with fuel rail-to-cylinder head bolts loosely installed. Ensure fuel injectors rotate smoothly. If fuel injectors do not rotate smoothly, check for improper "O" ring installation and replace "O" ring on fuel injector. 4. Ensure electrical connector on each fuel injector is facing toward valve cover. Tighten fuel rail-tocylinder head bolts and suspension upper brace bolts/nuts to specification. See TORQUE SPECIFICATIONS . 5. Operate fuel pump and check for fuel leaks. See FUEL PUMP OPERATION under FUEL SYSTEMS in BASIC DIAGNOSTIC PROCEDURES - 4-CYLINDER article.

2002 ENGINE PERFORMANCE Removal, Overhaul & Installation - 4-Cylinder

Fig. 87: Exploded View Of Fuel Rail & Components (MR2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Removal (Prius)

WARNING: Read service precautions before proceeding with service procedure. See SERVICE PRECAUTIONS . 1. Release fuel pressure. See FUEL SYSTEM PRESSURE RELEASE . Remove air cleaner assembly on top of engine for access to ignition coils and valve cover. Remove ignition coils, valve cover and

2002 ENGINE PERFORMANCE Removal, Overhaul & Installation - 4-Cylinder

gasket. See Fig. 88 . 2. Ensure area around fuel pipe at end of fuel rail and disconnect fitting is clean. See Fig. 89 . CAUTION: Use care when disconnecting fuel pipe, as some residual fuel pressure may still exist in the fuel system. 3. Depress both sides of retainer and pull fuel pipe with disconnect fitting from fuel pipe fitting. See Fig. 89 . 4. Note location of electrical connectors on fuel injectors for installation reference. Disconnect electrical connectors at fuel injectors. CAUTION: When removing fuel rail, use care not to allow fuel injectors to fall from fuel rail. 5. Remove bolt from fuel pipe clamp at the cylinder head. See Fig. 88 . Remove fuel rail-to-cylinder head bolts. Remove fuel rail with fuel injectors as an assembly. Remove the 2 spacers from cylinder head. Remove fuel injectors from fuel rail. Remove "O" ring and grommet from fuel injector.
Installation

1. To install, reverse removal procedure using NEW grommets and "O" rings. Coat "O" ring with gasoline before installing "O" ring on fuel injector. 2. Coat fuel rail "O" ring contact area with gasoline before installing fuel injector on fuel rail. Use twisting motion when installing fuel injector on fuel rail. Ensure electrical connector on each fuel injector is facing toward valve cover and the 2 spacers are installed on cylinder head before installing fuel rail. Coat grommet contact surfaces with gasoline before installing fuel rail with fuel injectors. 3. Install fuel rail with fuel injectors on cylinder head with fuel rail-to-cylinder head bolts loosely installed. Ensure fuel injectors rotate smoothly. If fuel injectors do not rotate smoothly, check for improper "O" ring installation and replace "O" ring on fuel injector. 4. Ensure electrical connector on each fuel injector is facing toward valve cover. Tighten fuel rail-tocylinder head bolts and fuel pipe clamp-to-cylinder head bolt to specification. See TORQUE SPECIFICATIONS . 5. Apply sealant at specified areas on cylinder head before installing gasket and valve cover. See Fig. 84 . Using NEW seal washers, install valve cover bolts/nuts. Tighten valve cover bolts/nuts to specification in sequence. See TORQUE SPECIFICATIONS . See Fig. 85 . Install ignition coils and tighten ignition coil bolts to specification. See TORQUE SPECIFICATIONS . CAUTION: DO NOT reuse old retainer when installing fuel pipe on fuel pipe fitting. Always use a NEW retainer. 6. Apply light coat of engine oil on tip of fuel pipe fitting to allow for ease of disconnect fitting and fuel pipe installation. Using NEW retainer, install fuel pipe on fuel pipe fitting until "click" sound is heard. DO NOT reuse old retainer. Pull on fuel pipe to ensure fuel pipe is properly locked on fuel pipe fitting. 7. Reinstall air cleaner assembly. Operate fuel pump and check for fuel leaks. See FUEL PUMP OPERATION under FUEL SYSTEMS in BASIC DIAGNOSTIC PROCEDURES - 4-CYLINDER article.

2002 ENGINE PERFORMANCE Removal, Overhaul & Installation - 4-Cylinder

Fig. 88: Exploded View Of Fuel Rail & Components (Prius) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 ENGINE PERFORMANCE Removal, Overhaul & Installation - 4-Cylinder

Fig. 89: Locating Fuel Pipe, Disconnect Fitting & Disconnecting Fuel Pipe From Fuel Pipe Fitting (Prius) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Removal (RAV4)

1. Release fuel pressure. See FUEL SYSTEM PRESSURE RELEASE . Disconnect PCV hose from valve cover for access to fuel rail. See Fig. 90 . 2. Remove air cleaner assembly for access to fuel rail. Note location of electrical connectors on fuel injectors for installation reference. Disconnect electrical connectors at fuel injectors. CAUTION: When removing fuel rail, use care not to allow fuel injectors to fall from fuel rail. 3. Remove fuel rail-to-cylinder head bolts. Remove fuel rail with fuel injectors as an assembly. Remove the 2 spacers and 4 grommets from cylinder head. Remove fuel injectors from fuel rail. Remove "O" ring from fuel injector.
Installation

2002 ENGINE PERFORMANCE Removal, Overhaul & Installation - 4-Cylinder

1. To install, reverse removal procedure using NEW grommets and "O" rings. Coat "O" ring with gasoline before installing "O" ring on fuel injector. 2. Coat fuel rail "O" ring contact area with gasoline before installing fuel injector on fuel rail. Use twisting motion when installing fuel injector on fuel rail. Ensure electrical connector on each fuel injector is facing away from valve cover and the 2 spacers and 4 grommets are installed on cylinder head before installing fuel rail. 3. Install fuel rail with fuel injectors on cylinder head with fuel rail-to-cylinder head bolts loosely installed. Ensure fuel injectors rotate smoothly. If fuel injectors do not rotate smoothly, check for improper "O" ring installation and replace "O" ring on fuel injector. 4. Ensure electrical connector on each fuel injector is facing away from valve cover. Tighten fuel rail-tocylinder head bolts to specification. See TORQUE SPECIFICATIONS . Operate fuel pump and check for fuel leaks. See FUEL PUMP OPERATION under FUEL SYSTEMS in BASIC DIAGNOSTIC PROCEDURES - 4-CYLINDER article.

Fig. 90: Exploded View Of Fuel Rail & Components (RAV4) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Removal (Tacoma)

1. Release fuel pressure. See FUEL SYSTEM PRESSURE RELEASE . Remove air cleaner hose and

2002 ENGINE PERFORMANCE Removal, Overhaul & Installation - 4-Cylinder

intake air connector for access to fuel rail and fuel injectors. See Fig. 91 . 2. Note location of electrical connectors on fuel injectors for installation reference. Disconnect electrical connectors at fuel injectors. Disconnect air hose and fuel return hose from fuel pressure regulator. 3. Remove union bolt with gaskets and disconnect fuel inlet pipe from fuel rail. See Fig. 91 . CAUTION: When removing fuel rail, use care not to allow fuel injectors to fall from fuel rail. 4. Remove fuel rail-to-cylinder head bolts. Remove fuel rail with fuel injectors. Remove 4 insulators from spacers on cylinder head. See Fig. 92 . Remove fuel injectors from fuel rail. Remove "O" ring and grommet (except Calif. emission vehicles only) from fuel injector. See Fig. 91 .
Installation

1. To install, reverse removal procedure using NEW grommets, "O" rings, insulators and gaskets. Coat "O" ring with gasoline before installing "O" ring on fuel injector. Coat fuel rail "O" ring contact area with gasoline before installing fuel injector on fuel rail. 2. Use twisting motion when installing fuel injector on fuel rail. Ensure electrical connector on each fuel injector is facing toward intake manifold and the 4 insulators are installed on spacers on the cylinder head. See Fig. 92 . 3. With fuel rail installed, loosely install fuel rail-to-cylinder head bolts. Ensure fuel injectors rotate smoothly. If fuel injectors fail to rotate smoothly, check for improper "O" ring installation and replace "O" ring on fuel injector. 4. Ensure electrical connector on each fuel injector is facing toward intake manifold. Tighten fuel rail-tocylinder head bolts and fuel inlet pipe-to-fuel rail union bolt to specification. See TORQUE SPECIFICATIONS . Operate fuel pump and check for fuel leaks. See FUEL PUMP OPERATION under FUEL SYSTEMS in BASIC DIAGNOSTIC PROCEDURES - 4-CYLINDER article.

2002 ENGINE PERFORMANCE Removal, Overhaul & Installation - 4-Cylinder

Fig. 91: Exploded View Of Fuel Rail & Components (Tacoma) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 ENGINE PERFORMANCE Removal, Overhaul & Installation - 4-Cylinder

Fig. 92: Locating Insulators (Tacoma) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. THROTTLE BODY
Removal & Installation (Camry & Camry Solara)

1. Drain cooling system. Remove upper cap on air cleaner assembly with air cleaner hose. Disconnect coolant hoes, vacuum hose and electrical connector at throttle body. Remove bolts, throttle body and gasket from intake manifold. 2. Manufacturer does not provide information for servicing of throttle control motor and Throttle Position (TP) sensor. To install, reverse removal procedure using NEW gasket. Ensure gasket for throttle body is installed so protrusion (if equipped) aligns with groove on intake manifold. See Fig. 93 . Tighten throttle body bolts to specification. See TORQUE SPECIFICATIONS . Fill cooling system.

2002 ENGINE PERFORMANCE Removal, Overhaul & Installation - 4-Cylinder

Fig. 93: Installing Gasket For Throttle Body (Camry, Camry Solara, Highlander & RAV4) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Removal (Celica & Corolla)

1. Drain cooling system. On Celica, remove No. 2 cylinder head cover located on top of engine, above ignition coils and valve cover. See Fig. 78 . On all models, remove upper cap on air cleaner assembly with air cleaner hose. 2. Disconnect control cable(s), coolant hoses, PCV hose and electrical connectors at throttle body. Remove bolts/nuts, throttle body and gasket from intake manifold. Remove retaining screws, Idle Air Control (IAC) valve and gasket from bottom of throttle body (if necessary).
Installation

1. To install, reverse removal procedure using NEW gasket. Ensure gasket for throttle body is installed with protrusion facing proper direction. See Fig. 94 and Fig. 95 . 2. Tighten throttle body bolts/nuts to specification. See TORQUE SPECIFICATIONS . On Celica, fill and bleed cooling system. See COOLING SYSTEM BLEEDING under COOLING SYSTEM. On Corolla, fill cooling system.

2002 ENGINE PERFORMANCE Removal, Overhaul & Installation - 4-Cylinder

Fig. 94: Installing Gasket For Throttle Body (Celica) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 ENGINE PERFORMANCE Removal, Overhaul & Installation - 4-Cylinder

Fig. 95: Installing Gasket For Throttle Body (Corolla) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Removal & Installation (ECHO)

1. Drain cooling system. Remove air cleaner hose that fits between throttle body and air cleaner assembly. Disconnect control cable(s), coolant hoses, PCV hose and electrical connectors at throttle body. Remove bolts/nuts, throttle body and gasket from intake manifold. Remove retaining screws, Idle Air Control (IAC) valve and gasket from bottom throttle body (if necessary). 2. To install, reverse removal procedure using NEW gasket. Tighten throttle body bolts/nuts to specification. See TORQUE SPECIFICATIONS . Fill cooling system.
Removal (Highlander)

1. Drain cooling system. Remove upper cap on air cleaner assembly with air cleaner hose. Disconnect control cable(s), coolant hoses, vacuum hose and electrical connectors at throttle body. Remove bolts, throttle body and gasket from intake manifold. 2. Remove retaining screws, Idle Air Control (IAC) valve and gasket from bottom of throttle body (if necessary). Remove retaining screws and Throttle Position (TP sensor) from throttle body (if necessary).
Installation

1. To install, reverse removal procedure using NEW gasket. If installing TP sensor, ensure throttle valve on throttle body is fully closed. Position TP sensor at 45 degrees to so it aligns with shaft on throttle valve and install on throttle body. See Fig. 30 . Rotate TP sensor to the right 45 degress and install and tighten retaining screws.

2002 ENGINE PERFORMANCE Removal, Overhaul & Installation - 4-Cylinder

2. Ensure gasket for throttle body is installed so protrusion aligns with groove on intake manifold. See Fig. 93 . Tighten throttle body bolts to specification. See TORQUE SPECIFICATIONS . Fill cooling system.
Removal & Installation (MR2 With Standard Type Manual Transaxle)

NOTE:

On MR2 there are 2 types of throttle bodies used depending on type of transaxle used. On models with a standard type manual transaxle, the driver operates the clutch and shifts the transaxle. On models with sequential manual transaxle, the transaxle is electronically controlled and the clutch is operated and transaxle is shifted hydraulically by moving the shift lever forward or backward. Sequential manual transaxle may be identified by shift lever pattern which consists of "R", "N", "S" and "+" in place of the conventional type shift lever pattern and no clutch pedal is used.

1. Drain cooling system. Remove suspension upper brace. Suspension upper brace fits between strut towers and is bolted to top of each strut tower. Remove air cleaner hose that fits between throttle body and air cleaner assembly. 2. Disconnect control cable(s), coolant hoses, PCV hose and electrical connectors at throttle body. Remove bolts/nuts, throttle body and gaskets from intake manifold. Remove retaining screws, Idle Air Control (IAC) valve and gasket from bottom of throttle body (if necessary). 3. To install, reverse removal procedure using NEW gaskets. Ensure gaskets for throttle body are installed in proper sequence, as 2 gaskets are used and that protrusion on the one gasket is properly positioned. See Fig. 96 . 4. Tighten throttle body bolts/nuts and suspension upper brace bolts/nuts to specification. See TORQUE SPECIFICATIONS . Fill and bleed cooling system. See COOLING SYSTEM BLEEDING under COOLING SYSTEM.

2002 ENGINE PERFORMANCE Removal, Overhaul & Installation - 4-Cylinder

Fig. 96: Installing Gaskets For Throttle Body (MR2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Removal (MR2 With Sequential Manual Transaxle)

1. Drain cooling system. Remove suspension upper brace. Suspension upper brace fits between strut towers and is bolted to top of each strut tower. Remove air cleaner hose that fits between throttle body and air cleaner assembly. 2. Disconnect control cable(s), coolant hoses, PCV hose and electrical connectors at throttle body. Remove bolts/nuts, throttle body support bracket near bottom of throttle body, throttle body and gaskets from intake manifold. Throttle Position (TP) sensor and accelerator pedal position sensor may be serviced. Throttle control motor is nonserviceable. If throttle control motor is defective, throttle body must be replaced.

2002 ENGINE PERFORMANCE Removal, Overhaul & Installation - 4-Cylinder

Disassembly

1. If necessary to remove TP sensor, remove TP sensor retaining screws and TP sensor from throttle body. See Fig. 97 . Use care not to drop or damage TP sensor. 2. If necessary to remove accelerator pedal position sensor, remove retaining bolts and accelerator pedal position sensor from throttle body. See Fig. 97 . Use care not to drop or damage accelerator pedal position sensor.

Fig. 97: Locating Accelerator Pedal Position Sensor, Throttle Position Sensor & Throttle Control Motor (MR2 With Sequential Manual Transaxle) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Reassembly

1. To install accelerator pedal position sensor, install accelerator pedal position sensor on throttle body. Tighten accelerator pedal position sensor bolts to specification. See TORQUE SPECIFICATIONS . 2. To check accelerator pedal position sensor operation after installation on throttle body, install electrical connector on accelerator pedal position sensor. Connect Toyota hand-held tester or scan tool to data link connector No. 3. See Fig. 98 . 3. Turn ignition on. DO NOT depress accelerator pedal or rotate accelerator pedal position sensor after turning ignition on. Using hand-held tester or scan tool, check that ACCEL POS#1 (VPA) voltage of the CURRENT DATA is .3-.9 volt. This is the standard accelerator pedal position sensor voltage. Turn ignition off. Disconnect electrical connector at accelerator pedal position sensor. 4. To install TP sensor, ensure throttle valve opening on throttle body is about 4 degrees. Install TP sensor on throttle body so it is at position No. 1 (15 degrees) and loosely install TP sensor retaining screws. See Fig. 99 . Rotate TP sensor counterclockwise to position No. 2 until it contacts throttle valve and slightly tighten TP sensor retaining screws. See Fig. 99 .

2002 ENGINE PERFORMANCE Removal, Overhaul & Installation - 4-Cylinder

NOTE:

Ensure electrical connector is not installed on accelerator pedal position sensor when checking TP sensor adjustment.

5. To check TP sensor adjustment after installation on throttle body, install electrical connector on TP sensor. Ensure electrical connector is NOT installed on accelerator pedal position sensor. Connect Toyota hand-held tester or scan tool to data link connector No. 3. See Fig. 98 . Turn ignition on. DO NOT depress accelerator pedal or rotate accelerator pedal position sensor after turning ignition on when adjusting TP sensor. 6. Using hand-held tester or scan tool, read the throttle valve opening which is displayed as a percentage. Throttle valve opening may be read by accessing THROTTLE POS under CURRENT DATA on hand-held tester or scan tool. 7. While reading throttle valve opening, rotate TP sensor clockwise and counterclockwise until throttle valve opening is 15.2 percent, as this is the center of the standard throttle valve opening of 14.4-16.0 percent. Tighten TP sensor retaining screws to specification. See TORQUE SPECIFICATIONS . When TP sensor retaining screws are tightened, this may cause the throttle valve opening to change. Ensure throttle valve opening remains at 15.2 percent after TP sensor retaining screws are tightened. Readjust TP sensor if necessary. 8. Ensure throttle valve on throttle body is fully closed. Using hand-held tester or scan tool, read the throttle valve opening again. With throttle valve fully closed, throttle valve opening should be 10-14 percent. 9. If throttle valve opening is not within specification with throttle valve fully closed, repeat steps 5 through 8 until correct throttle valve opening is obtained. Turn ignition off. Remove hand-held tester or scan tool. Disconnect electrical connector at TP sensor.

2002 ENGINE PERFORMANCE Removal, Overhaul & Installation - 4-Cylinder

Fig. 98: Locating Data Link Connector No. 3 (MR2 With Sequential Manual Transaxle) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 99: Installing Throttle Position Sensor (MR2 With Sequential Manual Transaxle) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Installation

1. To install, reverse removal procedure using NEW gaskets. Ensure gaskets for throttle body are installed in proper sequence, as 2 gaskets are used and that protrusion on the one gasket is properly positioned. See Fig. 96 . 2. Tighten throttle body bolts/nuts, throttle body support bracket bolts and suspension upper brace bolts/nuts to specification. See TORQUE SPECIFICATIONS . Fill and bleed cooling system. See COOLING SYSTEM BLEEDING under COOLING SYSTEM.
Removal (Prius)

WARNING: Read service precautions before proceeding with service procedure. See SERVICE PRECAUTIONS .

2002 ENGINE PERFORMANCE Removal, Overhaul & Installation - 4-Cylinder

Drain cooling system. Remove air cleaner assembly on top of engine for access to throttle body. Disconnect coolant hoses, PCV hose and electrical connectors at throttle body. Remove bolts/nuts, throttle body and gasket from intake manifold. Throttle Position (TP) sensor may be serviced. Throttle control motor is nonserviceable. If throttle control motor is defective, throttle body must be replaced.
Disassembly & Reassembly

1. If necessary to remove TP sensor, remove TP sensor retaining screws and TP sensor from throttle body. See Fig. 100 . Use care not to drop or damage TP sensor. 2. To install TP sensor, ensure throttle valve opening on throttle body is about 3.5 degrees. Install TP sensor on throttle body so it is at position No. 1 (15 degrees) and loosely install TP sensor retaining screws. See Fig. 101 . Rotate TP sensor counterclockwise to position No. 2 until it contacts throttle valve and slightly tighten TP sensor retaining screws. See Fig. 101 . NOTE: Ensure electrical connector is not installed on throttle control motor when checking TP sensor adjustment.

3. To check TP sensor adjustment after installation on throttle body, install electrical connector on TP sensor. Ensure electrical connector is NOT installed on throttle control motor. Connect Toyota handheld tester to data link connector No. 3. See Fig. 102 . Turn ignition on. DO NOT depress accelerator pedal after turning ignition on when adjusting TP sensor. 4. Using hand-held tester, read the throttle valve opening which is displayed as a percentage. Throttle valve opening may be read by accessing THROTTLE POS under CURRENT DATA on hand-held tester. 5. While reading throttle valve opening, rotate TP sensor counterclockwise until throttle valve opening is 14.8 percent, as this is the center of the standard throttle valve opening of 14.0-15.6 percent. Tighten TP sensor retaining screws to specification. See TORQUE SPECIFICATIONS . When TP sensor retaining screws are tightened, this may cause the throttle valve opening to change. Ensure throttle valve opening remains at 14.8 percent after TP sensor retaining screws are tightened. Readjust TP sensor if necessary. 6. Ensure throttle valve on throttle body is fully closed. Using hand-held tester, read the throttle valve opening again. With throttle valve fully closed, throttle valve opening should be 10-14 percent. 7. If throttle valve opening is not within specification with throttle valve fully closed, repeat steps 5 and 6 until correct throttle valve opening is obtained. Turn ignition off. Remove hand-held tester. Disconnect electrical connector at TP sensor.
Installation

To install, reverse removal procedure using NEW gasket. Tighten throttle body bolts/nuts to specification. See TORQUE SPECIFICATIONS . Fill and bleed cooling system. See COOLING SYSTEM BLEEDING under COOLING SYSTEM.

2002 ENGINE PERFORMANCE Removal, Overhaul & Installation - 4-Cylinder

Fig. 100: Locating Throttle Position Sensor & Throttle Control Motor (Prius) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 ENGINE PERFORMANCE Removal, Overhaul & Installation - 4-Cylinder

Fig. 101: Installing Throttle Position Sensor (Prius) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 ENGINE PERFORMANCE Removal, Overhaul & Installation - 4-Cylinder

Fig. 102: Locating Data Link Connector No. 3 (Prius) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Removal & Installation (RAV4)

1. Drain cooling system. Remove air cleaner hose that fits between throttle body and air cleaner assembly. Disconnect control cable(s), coolant hoses, vacuum hose and electrical connectors at throttle body. Remove bolts, throttle body and gasket from intake manifold. Remove retaining screws, Idle Air Control (IAC) valve and gasket from side of throttle body (if necessary). 2. To install, reverse removal procedure using NEW gasket. Ensure gasket for throttle body is installed so protrusion on gasket aligns with groove on intake manifold. See Fig. 93 . Tighten throttle body bolts to specification. See TORQUE SPECIFICATIONS . Fill cooling system.
Removal & Installation (Tacoma)

1. Drain cooling system. Remove air cleaner hose and intake air connector. See Fig. 91 . 2. Disconnect control cable(s), PCV hose, air hose, vacuum hoses and electrical connectors at throttle body. Remove bolts/nuts, throttle body and gasket from intake manifold. Disconnect remaining coolant hoses from bottom of throttle body. Remove throttle body. Remove screws, Idle Air Control (IAC) valve and gasket from bottom of throttle body (if necessary). 3. To install, reverse removal procedure using NEW gasket. Tighten throttle body bolts/nuts to specification. See TORQUE SPECIFICATIONS . Fill cooling system IDLE AIR CONTROL VALVE

2002 ENGINE PERFORMANCE Removal, Overhaul & Installation - 4-Cylinder

Removal & Installation (Celica, Corolla, ECHO, Highlander, MR2 With Standard Type Manual Transaxle, RAV4 & Tacoma)

Idle Air Control (IAC) valve is located on throttle body. See THROTTLE BODY for servicing of IAC valve.

EMISSION SYSTEMS & SUB-SYSTEMS

CANISTER CLOSED VALVE VACUUM SWITCHING VALVE
Removal & Installation (Camry, Camry Solara, Celica, Corolla, Highlander, MR2, RAV4 & Tacoma)

Canister Closed Valve Vacuum Switching Valve (CCV VSV) servicing procedure is just primarily an unbolt and bolt-on procedure. For illustration of CCV VSV, see EMISSION SYSTEMS & SUB-SYSTEMS in SYSTEM & COMPONENT TESTING - 4-CYLINDER article.
Removal & Installation (ECHO)

Canister Closed Valve Vacuum Switching Valve (CCV VSV) is located on charcoal canister. See Fig. 103 . Charcoal canister is located near fuel tank. Remove charcoal canister. Remove bracket for access to CCV VSV if necessary. See Fig. 103 . Remove screw and CCV VSV with "O" ring from charcoal canister. To install, reverse removal procedure using NEW "O" ring.

Fig. 103: Locating Canister Closed Valve Vacuum Switching Valve (ECHO) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Removal (Prius)

WARNING: Read service precautions before proceeding with service procedure. See SERVICE PRECAUTIONS . 1. Canister Closed Valve Vacuum Switching Valve (CCV VSV) is located on top of fuel tank. See Fig.

2002 ENGINE PERFORMANCE Removal, Overhaul & Installation - 4-Cylinder

104 . Fuel tank must be removed for access to CCV VSV. Release fuel pressure. See FUEL SYSTEM PRESSURE RELEASE . 2. Remove rear seat cushion and cover plate on floor panel for access to fuel pump if not previously done. Disconnect electrical connector from top of fuel pump. This is electrical connector for fuel pump and fuel gauge sending unit. Electric fuel pump is located in the fuel tank. 3. Raise and support vehicle. Remove exhaust pipe assembly and tailpipe for access to fuel tank. Drain gasoline from fuel tank into approved container. Disconnect fuel filler tube and any remaining hoses for fuel tank removal. Support fuel tank with transmission jack. Remove fuel tank retaining bolts and fuel tank. 4. Disconnect necessary hoses and electrical connectors for removal of CCV VSV and fresh air valve. Remove bolt and separate fresh air valve from CCV VSV. See Fig. 104 . Remove bolts for CCV VSV and remove CCV VSV along with trap filter and seal packing. Remove bolts and separate CCV VSV from trap filter.
Installation

To install, reverse removal procedure using NEW seal packing on trap filter and gasket on exhaust pipe at exhaust manifold. Tighten fuel tank retaining bolts and exhaust pipe-to-exhaust manifold bolts to specification. See TORQUE SPECIFICATIONS . Operate fuel pump and check for fuel leaks. See FUEL PUMP OPERATION under FUEL SYSTEMS in BASIC DIAGNOSTIC PROCEDURES - 4-CYLINDER article.

2002 ENGINE PERFORMANCE Removal, Overhaul & Installation - 4-Cylinder

Fig. 104: Locating Canister Closed Valve Vacuum Switching Valve, Fresh Air Valve & Trap Filter (Prius) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. CHARCOAL CANISTER
Removal & Installation (All Models)

WARNING: On Prius, read service precautions before proceeding with service procedure. See SERVICE PRECAUTIONS .

2002 ENGINE PERFORMANCE Removal, Overhaul & Installation - 4-Cylinder

Charcoal canister is located near fuel tank. For illustration of charcoal canister location, see EMISSION SYSTEMS & SUB-SYSTEMS in SYSTEM & COMPONENT TESTING - 4-CYLINDER article. Service information is not available from manufacturer. EGR GAS TEMPERATURE SENSOR
Removal & Installation (Tacoma 2.7L 4-Cyl. 3RZ-FE)

See EGR GAS TEMPERATURE SENSOR under ENGINE SENSORS & SWITCHES. EGR VACUUM SWITCHING VALVE
Removal & Installation (Tacoma 2.7L 3RZ-FE)

EGR Vacuum Switching Valve (VSV) servicing procedure is just primarily an unbolt and bolt-on procedure. EGR VSV is located on bracket, near throttle body and contains Green 2-pin electrical connector with White/Red and Red/Black wires. EGR VALVE
Removal & Installation (Tacoma 2.7L 3RZ-FE)

EGR valve servicing procedure is just primarily an unbolt and bolt-on procedure using a NEW gasket. Tighten EGR valve retaining nuts and EGR pipe bolts/nuts to specification. See TORQUE SPECIFICATIONS . EVAP VACUUM SWITCHING VALVE
Removal & Installation (All Models)

WARNING: On Prius, read service precautions before proceeding with service procedure. See SERVICE PRECAUTIONS . EVAP Vacuum Switching Valve (VSV) servicing procedure is just primarily an unbolt and bolt-on procedure. See EVAP VACUUM SWITCHING VALVE LOCATION table. For illustration of EVAP VSV location, see EMISSION SYSTEMS & SUB-SYSTEMS in SYSTEM & COMPONENT TESTING 4-CYLINDER article. EVAP VACUUM SWITCHING VALVE LOCATION Application Location Camry On Air Cleaner Housing & Contains Blue or Black 2-Pin Electrical Connector With Black/White & Black/Red Wires Camry Solara On Air Intake Hose, Near Air Cleaner Assembly & Contains Black 2Pin Electrical Connector With Black/White & Black/Red Wires Celica On Bracket At Rear Of Air Cleaner Housing & Contains Black 2-Pin Electrical Connector With Green/Orange & Black/White Wires Corolla On Bracket At Rear Of Air Cleaner Housing & Contains Black 2-Pin Electrical Connector With Blue/Black & Black Wires ECHO On Bracket At Side Of Air Cleaner Housing & Contains Blue 2-Pin

2002 ENGINE PERFORMANCE Removal, Overhaul & Installation - 4-Cylinder

Highlander MR2 Prius

RAV4 Tacoma

Electrical Connector With Black/Yellow & White/Green Wires On Rear Of Air Cleaner Housing & Contains Blue 2-Pin Electrical Connector With Black/White & Black/Red Wires On Air Intake Hose, Near Air Cleaner Assembly & Contains Blue 2-Pin Electrical Connector With Black/Red & White Wires At Passenger's Side Front Corner Of Engine Compartment, Near Air Intake Hose & Contains Blue 2-Pin Electrical Connector With Red/Blue & Black Wires On Air Intake Hose, Near Air Cleaner Assembly & Contains Black 2Pin Electrical Connector With Black/Red & Pink Wires On Bracket Bolted To Inside Of Driver's Side Front Fender Panel & Contains Black 2-Pin Electrical Connector With White/Green & White/Red Wires

FRESH AIR VALVE

Removal & Installation (Prius)

WARNING: Read service precautions before proceeding with service procedure. See SERVICE PRECAUTIONS . Fresh air valve is located on top of fuel tank. See Fig. 104 . For servicing of fresh air valve, see CANISTER CLOSED VALVE VACUUM SWITCHING VALVE . HYDROCARBON ADSORBER CATALYST VACUUM SWITCHING VALVE
Removal & Installation (Prius)

WARNING: Read service precautions before proceeding with service procedure. See SERVICE PRECAUTIONS . Hydrocarbon Adsorber Catalyst (HCAC) Vacuum Switching Valve (VSV) servicing procedure is just primarily an unbolt and bolt-on procedure. HCAC VSV is located on bracket bolted to timing chain end of engine and uses a Brown 2-pin electrical connector with Black and Black/White wires. See Fig. 105 .

2002 ENGINE PERFORMANCE Removal, Overhaul & Installation - 4-Cylinder

Fig. 105: Locating Hydrocarbon Adsorber Catalyst Vacuum Switching Valve (Prius) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. PRESSURE SWITCHING VALVE VACUUM SWITCHING VALVE
Removal & Installation (Camry, Camry Solara, Celica, Corolla, Highlander, MR2, RAV4 & Tacoma)

Pressure switching valve Vacuum Switching Valve (VSV) servicing procedure is just primarily an unbolt

2002 ENGINE PERFORMANCE Removal, Overhaul & Installation - 4-Cylinder

and bolt-on procedure. See PRESSURE SWITCHING VALVE VSV LOCATION table. For illustration of pressure switching valve VSV location, see EMISSION SYSTEMS & SUB-SYSTEMS in SYSTEM & COMPONENT TESTING - 4-CYLINDER article. PRESSURE SWITCHING VALVE VSV LOCATION Application Location Camry On Bracket At Charcoal Canister Near Fuel Tank & Contains Blue 2-Pin Electrical Connector With Violet & Black/Red Wires Camry Solara On Bracket At Charcoal Canister Near Fuel Tank & Contains Blue 2-Pin Electrical Connector With White/Red & Red Wires Celica On Bracket At Charcoal Canister Near Fuel Tank & Contains Blue 2-Pin Electrical Connector With Green/Orange & Black/White Wires Corolla On Bracket At Charcoal Canister Near Fuel Tank & Contains Black 2-Pin Electrical Connector With Red & Black Wires Highlander On Bracket At Charcoal Canister Near Fuel Tank & Contains Blue 2-Pin Electrical Connector With White & Green/Yellow Wires MR2 Below Driver's Side Luggage Compartment, On Bracket At Charcoal Canister Near Fuel Tank & Contains Blue 2-Pin Electrical Connector With Blue/White & Black/Red Wires RAV4 On Bracket At Charcoal Canister Near Fuel Tank & Contains Blue 2-Pin Electrical Connector With Green/Orange & Black/Red Wires Tacoma On Bracket At Charcoal Canister Near Fuel Tank & Contains Blue 2-Pin Electrical Connector With Green/Black & White/Red Wires PURGE FLOW SWITCHING VALVE VACUUM SWITCHING VALVE
Removal & Installation (Prius)

WARNING: Read service precautions before proceeding with service procedure. See SERVICE PRECAUTIONS . 1. Purge flow switching valve Vacuum Switching Valve (VSV) is located on bracket at charcoal canister on top of fuel tank and contains Blue 2-pin electrical connector with Black and Black/Red wires. See Fig. 106 . Manufacturer states fuel tank must be removed for access to purge flow switching valve VSV. Release fuel pressure. See FUEL SYSTEM PRESSURE RELEASE . 2. Remove rear seat cushion and cover plate on floor panel for access to fuel pump if not previously done. Disconnect electrical connector from top of fuel pump. This is electrical connector for fuel pump and fuel gauge sending unit. Electric fuel pump is located in the fuel tank. 3. Raise and support vehicle. Remove exhaust pipe assembly and tailpipe for access to fuel tank. Drain gasoline from fuel tank into approved container. Disconnect fuel filler tube and any remaining hoses for fuel tank removal. Support fuel tank with transmission jack. Remove fuel tank retaining bolts and fuel tank. 4. Disconnect necessary hoses and electrical connector for removal of purge flow switching valve VSV. Remove retaining bolts and purge flow switching valve. To install, reverse removal procedure using NEW gasket on exhaust pipe at exhaust manifold. Tighten fuel tank retaining bolts and exhaust pipeto-exhaust manifold bolts to specification. See TORQUE SPECIFICATIONS . Operate fuel pump and check for fuel leaks. See FUEL PUMP OPERATION under FUEL SYSTEMS in BASIC DIAGNOSTIC PROCEDURES - 4-CYLINDER article.

2002 ENGINE PERFORMANCE Removal, Overhaul & Installation - 4-Cylinder

Fig. 106: Locating Purge Flow Switching Valve Vacuum Switching Valve (Prius) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TRAP FILTER
Removal & Installation (Prius)

WARNING: Read service precautions before proceeding with service procedure. See SERVICE PRECAUTIONS . Trap filter is located on top of fuel tank. See Fig. 104 . For servicing of trap filter, see CANISTER CLOSED VALVE VACUUM SWITCHING VALVE . VAPOR PRESSURE SENSOR

2002 ENGINE PERFORMANCE Removal, Overhaul & Installation - 4-Cylinder

Removal & Installation (Camry & Highlander)

Information is not available from manufacturer.

Removal & Installation (Camry Solara & Corolla)

Service information is not available from manufacturer. On Camry Solara, vapor pressure sensor is located on charcoal canister near fuel tank and contains Black 3-pin electrical connector with Blue/Red, Brown and Yellow wires. On Corolla, vapor pressure sensor is located on charcoal canister near fuel tank and contains Black 3-pin electrical connector with Brown, Blue and Yellow wires. For illustration of vapor pressure sensor location, see EMISSION SYSTEMS & SUB-SYSTEMS in SYSTEM & COMPONENT TESTING - 4-CYLINDER article.
Removal & Installation (Celica & ECHO)

Vapor pressure sensor is located on top of fuel pump. See Fig. 54 and Fig. 61 . Remove rear seat cushion and cover plate on floor panel for access to vapor pressure sensor. Disconnect electrical connector at vapor pressure sensor. Ensure area around vapor pressure sensor is clean. Remove retaining clip and vapor pressure sensor. To install reverse removal procedure.
Removal & Installation (MR2)

1. Vapor pressure sensor is located on top of fuel pump. See Fig. 65 . Apply tape to end of screwdriver to prevent scratching interior components. Using screwdriver, remove door opening scuff plates, lower trim covers and quarter trim covers. See Fig. 4 . Remove luggage compartment lids, luggage compartment boxes and cover plate on floor panel for access to vapor pressure sensor. 2. Remove bolts and fuel pump protector cover located on fuel tank, above fuel pump. Disconnect electrical connector at vapor pressure sensor. Ensure area around vapor pressure sensor is clean. Remove retaining clip located just below the vapor pressure sensor. Remove vapor pressure sensor. To install reverse removal procedure.
Removal (Prius)

WARNING: Read service precautions before proceeding with service procedure. See SERVICE PRECAUTIONS . 1. Vapor pressure sensor is located at top corner of fuel tank. See Fig. 107 . Manufacturer states fuel tank must be removed for access to vapor pressure sensor. Release fuel pressure. See FUEL SYSTEM PRESSURE RELEASE . 2. Remove rear seat cushion and cover plate on floor panel for access to fuel pump if not previously done. Disconnect electrical connector from top of fuel pump. This is electrical connector for fuel pump and fuel gauge sending unit. Electric fuel pump is located in the fuel tank. 3. Raise and support vehicle. Remove exhaust pipe assembly and tailpipe for access to fuel tank. Drain gasoline from fuel tank into approved container. Disconnect fuel filler tube and any remaining hoses for fuel tank removal. Support fuel tank with transmission jack. Remove fuel tank retaining bolts and fuel tank. 4. Disconnect electrical connector at vapor pressure sensor. Ensure area around vapor pressure sensor is clean. Remove retaining clip and vapor pressure sensor from mounting flange. Use care not to scratch vapor pressure sensor or vapor pressure sensor sealing surfaces. DO NOT use tools to remove vapor pressure sensor. Vapor pressure sensor should be removed from mounting flange by-hand.

2002 ENGINE PERFORMANCE Removal, Overhaul & Installation - 4-Cylinder

Installation

1. If mounting flange was removed from fuel tank, using NEW seal packing, install mounting flange in fuel tank. Ensure vapor pressure sensor and vapor pressure sensor sealing surfaces are clean and no scratches exist. Install vapor pressure sensor. Ensure vapor pressure sensor is fully seated in mounting flange. 2. Install retaining clip. Ensure retaining clip is fully seated in rim of vapor pressure sensor. Check that vapor pressure sensor cannot be pulled from mounting flange. To install remaining components, reverse removal procedure using NEW gasket on exhaust pipe at exhaust manifold. Tighten fuel tank retaining bolts and exhaust pipe-to-exhaust manifold bolts to specification. See TORQUE SPECIFICATIONS . Operate fuel pump and check for fuel leaks. See FUEL PUMP OPERATION under FUEL SYSTEMS in BASIC DIAGNOSTIC PROCEDURES - 4-CYLINDER article.

Fig. 107: Locating Vapor Pressure Sensor (Prius) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Removal & Installation (RAV4)

2002 ENGINE PERFORMANCE Removal, Overhaul & Installation - 4-Cylinder

Vapor pressure sensor is located on top of fuel pump. See Fig. 69 . Remove driver's side rear seat and cover plate on floor panel for access to vapor pressure sensor. Disconnect electrical connector at vapor pressure sensor. Ensure area around vapor pressure sensor is clean. Remove retaining clip and vapor pressure sensor. To install reverse removal procedure.
Removal & Installation (Tacoma)

Vapor pressure sensor is located on top of fuel pump. See Fig. 73 . Servicing information is not available from manufacturer.

VARIABLE VALVE LIFT SYSTEM

VARIABLE VALVE LIFT OIL CONTROL VALVE NOTE: Variable Valve Lift (VVL) oil control valve may also be referred to as VVL Oil Control Valve (OCV) or camshaft timing oil control valve (VVL) and is used with VVL system. VVL system may also be referred to as Variable Valve Timing Lift Intelligent (VVTL-I or VVTL-i) system.

Removal & Installation (Celica 1.8L 2ZZ-GE)

1. Variable Valve Lift (VVL) oil control valve is located at intake manifold side of cylinder head, near flywheel end of engine. See Fig. 110 . Remove No. 2 cylinder head cover located on top of engine, above ignition coils and valve cover, front fender apron seal and upper radiator support seal. See Fig. 12 . 2. Disconnect electrical connector at VVL oil control valve. Remove retaining bolt and VVL oil control valve with "O" ring from housing on rear of cylinder head. To install, reverse removal procedure using NEW "O" ring. Tighten retaining bolt to specification. See TORQUE SPECIFICATIONS .

VARIABLE VALVE TIMING SYSTEM

VARIABLE VALVE TIMING CAMSHAFT TIMING OIL CONTROL VALVE NOTE: Variable Valve Timing (VVT) camshaft timing oil control valve may also be referred to as oil control valve for VVT, VVT Oil Control Valve (OCV) or camshaft timing oil control valve VVT.

Removal & Installation (Camry, Camry Solara, Celica, Corolla, ECHO, Highlander, MR2, Prius & RAV4)

WARNING: On Prius, read service precautions before proceeding with service procedure. See SERVICE PRECAUTIONS . 1. Variable Valve Timing (VVT) camshaft timing oil control valve is located at intake manifold side of cylinder head, near timing chain end of engine. See Fig. 108 -Fig. 113 . Remove No. 2 cylinder head cover (if equipped) which is located on top of engine, above ignition coils and valve cover for access to VVT camshaft timing oil control valve. 2. On Celica, remove front fender apron seal, upper radiator support seal, generator and ventilation tube for access to VVT camshaft timing oil control valve. See Fig. 12 . On ECHO, remove generator bracket for access to VVT camshaft timing oil control valve. On MR2, remove suspension upper

2002 ENGINE PERFORMANCE Removal, Overhaul & Installation - 4-Cylinder

brace. Suspension upper brace fits between strut towers and is bolted to top of each strut tower. On Prius, remove air cleaner assembly on top of engine for access to VVT camshaft timing oil control valve. 3. On all models, disconnect electrical connector at VVT camshaft timing oil control valve. Remove retaining bolt and VVT camshaft timing oil control valve with "O" ring from cylinder head. To install, reverse removal procedure using NEW "O" ring. Tighten retaining bolt to specification (if available). See TORQUE SPECIFICATIONS .

Fig. 108: Locating Typical Variable Valve Timing Camshaft Timing Oil Control Valve (Camry, Camry Solara, Highlander & RAV4) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 ENGINE PERFORMANCE Removal, Overhaul & Installation - 4-Cylinder

Fig. 109: Locating Variable Valve Timing Camshaft Timing Oil Control Valve (Celica 1.8L 1ZZ-FE) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 ENGINE PERFORMANCE Removal, Overhaul & Installation - 4-Cylinder

Fig. 110: Locating Variable Valve Lift Oil Control Valve & Variable Valve Timing Camshaft Timing Oil Control Valve (Celica 1.8L 2ZZ-GE) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 ENGINE PERFORMANCE Removal, Overhaul & Installation - 4-Cylinder

Fig. 111: Locating Variable Valve Timing Camshaft Timing Oil Control Valve (Corolla) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 ENGINE PERFORMANCE Removal, Overhaul & Installation - 4-Cylinder

Fig. 112: Locating Variable Valve Timing Camshaft Timing Oil Control Valve (ECHO) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 ENGINE PERFORMANCE Removal, Overhaul & Installation - 4-Cylinder

Fig. 113: Locating Typical Variable Valve Timing Camshaft Timing Oil Control Valve (MR2 & Prius) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. VARIABLE VALVE TIMING SENSOR NOTE: Variable Valve Timing (VVT) sensor may also be referred to as camshaft position sensor.

Removal & Installation (Camry, Camry Solara, Celica, Corolla, ECHO, Highlander, MR2, Prius & RAV4)

For VVT sensor servicing, see CAMSHAFT POSITION SENSOR under IGNITION SYSTEMS.

TORQUE SPECIFICATIONS

2002 ENGINE PERFORMANCE Removal, Overhaul & Installation - 4-Cylinder

TORQUE SPECIFICATIONS (CAMRY) Application A/F Sensor ECT Sensor Fuel Rail-To-Cylinder Head Bolt Heated Oxygen Sensor Intake Manifold Bolt/Nut Knock Sensor Power Steering Pressure Switch Throttle Body Bolt Vehicle Speed Sensor Retaining Bolt Camshaft Position Sensor Bolt Control Lever Nut Crankshaft Position Sensor Bolt Fuel Pump Retaining Plate-To-Fuel Tank Bolt Ignition Coil Bolt PNP Switch Retaining Bolt PNP Switch Retaining Nut VVT Camshaft Timing Oil Control Valve Retaining Bolt (1) Information is not available from manufacturer. TORQUE SPECIFICATIONS (CAMRY SOLARA) Application A/F Sensor ECT Sensor Fuel Rail-To-Cylinder Head Bolt Heated Oxygen Sensor Intake Manifold Bolt/Nut Knock Sensor Power Steering Pressure Switch Throttle Body Bolt Accelerator Pedal Bracket Retaining Bolt Camshaft Position Sensor Bolt Control Lever Nut Crankshaft Position Sensor Bolt Fuel Pressure Regulator Retaining Screw Fuel Pump Protector Cover Bolt Fuel Pump Retaining Plate-To-Fuel Tank Bolt Ignition Coil Bolt PNP Switch Retaining Bolt PNP Switch Retaining Nut

Ft. Lbs. (N.m)

(1)

15 (20) 15 (20) 32 (43) 22 (30) 29 (39) 15 (20) 22 (30)

(1)

INCH Lbs. (N.m) 80 (9.0) 112 (12.7) 80 (9.0) 31 (3.5) 80 (9.0) 48 (5.4) 61 (6.9) 80 (9.0)

Ft. Lbs. (N.m) 32 (43) 15 (20) 15 (20) 32 (43) 22 (30) 32 (43) 15 (20) 22 (30) INCH Lbs. (N.m) 80 (9.0) 80 (9.0) 112 (12.7) 80 (9.0) 18 (2.0) 35 (4.0) 35 (4.0) 80 (9.0) 48 (5.4) 61 (6.9)

2002 ENGINE PERFORMANCE Removal, Overhaul & Installation - 4-Cylinder

Round Fuel Filter Retaining Screw Vehicle Speed Sensor Retaining Bolt VVT Camshaft Timing Oil Control Valve Retaining Bolt TORQUE SPECIFICATIONS (CELICA) Application ECT Sensor Fuel Rail-To-Cylinder Head Bolt 1.8L 1ZZ-FE 1.8L 2ZZ-GE Heated Oxygen Sensor Intake Manifold Bolt/Nut 1.8L 1ZZ-FE 1.8L 2ZZ-GE Intake Manifold Support Bolt/Nut 1.8L 2ZZ-GE Knock Sensor 1.8L 1ZZ-FE Knock Sensor Retaining Nut 1.8L 2ZZ-GE Power Steering Pressure Switch Throttle Body Bolt/Nut 1.8L 1ZZ-FE 1.8L 2ZZ-GE Camshaft Position Sensor Bolt Control Lever Nut Crankshaft Position Sensor Bolt Fuel Pipe Clamp-To-Cylinder Head Bolt Fuel Pump Retaining Plate-To-Fuel Tank Bolt Ignition Coil Bolt PNP Switch Retaining Bolt PNP Switch Retaining Nut Vehicle Speed Sensor Retaining Bolt A/T M/T VVL Oil Control Valve Retaining Bolt 1.8L 2ZZ-GE VVT Camshaft Timing Oil Control Valve Retaining Bolt 1.8L 1ZZ-FE 1.8L 2ZZ-GE (1) Information is not available from manufacturer.

18 (2.0) 49 (5.5) 78 (8.8)

Ft. Lbs. (N.m)

(1)

14 (19) 21 (29) 32 (43) 14 (19)

(2)

18 (24) 29 (39) 15 (20) 15 (20) 15 (20) 16 (22) INCH Lbs. (N.m) 78 (8.8) 115 (13.0) 78 (8.8) 80 (9.0) 35 (4.0) 80 (9.0) 48 (5.4) 61 (6.9) 49 (5.5) 97 (11.0) 75 (8.5) 66 (7.5) 75 (8.5)

(2) Tighten bolts/nuts "A" to 20 ft. lbs. (27 N.m) and bolt "B" to 34 ft. lbs. (46 N.m). See Fig. 14 .

2002 ENGINE PERFORMANCE Removal, Overhaul & Installation - 4-Cylinder

TORQUE SPECIFICATIONS (COROLLA) Application ECT Sensor Fuel Rail-To-Cylinder Head Bolt Heated Oxygen Sensor-To-Exhaust Pipe Behind Catalytic Converter Heated Oxygen Sensor-To-Exhaust Pipe Retaining Nut Intake Manifold Bolt/Nut Intake Manifold Support Bolt Knock Sensor Power Steering Pressure Switch Throttle Body Bolt/Nut Vehicle Speed Sensor Retaining Bolt A/T M/T Camshaft Position Sensor Bolt Control Lever Nut Crankshaft Position Sensor Bolt Fuel Pipe Clamp-To-Cylinder Head Bolt Fuel Pump Retaining Plate-To-Fuel Tank Bolt Ignition Coil Bolt PNP Switch Retaining Bolt PNP Switch Retaining Nut VVT Camshaft Timing Oil Control Valve Retaining Bolt
(1) Information is not available from manufacturer. (2) Tighten retaining bolt to 97 INCH lbs. (11.0 N.m).

Ft. Lbs. (N.m)

(1)

14 (19) 32 (43) 32 (43) 14 (19) 14 (19) 29 (39) 15 (20) 15 (20) 12 (16)

(2)

INCH Lbs. (N.m) 80 (9.0) 106 (12.0) 80 (9.0) 80 (9.0) 35 (4.0) 62 (7.0) 48 (5.4) 61 (6.9)
(1)

TORQUE SPECIFICATIONS (ECHO) Application ECT Sensor Fuel Rail-To-Cylinder Head Bolt Heated Oxygen Sensor Intake Manifold Bolt/Nut Knock Sensor Power Steering Pressure Sensor Throttle Body Bolt/Nut Camshaft Position Sensor Bolt Control Lever Nut Crankshaft Position Sensor Bolt Fuel Pipe Clamp-To-Cylinder Head Bolt Fuel Pump Retaining Plate-To-Fuel Tank Bolt Ignition Coil Bolt

Ft. Lbs. (N.m)

(1)

14 (19) 32 (43) 22 (30) 29 (39) 15 (20) 22 (30) INCH Lbs. (N.m) 71 (8.0) 115 (13.0) 66 (7.5) 80 (9.0) 35 (4.0) 80 (9.0)

2002 ENGINE PERFORMANCE Removal, Overhaul & Installation - 4-Cylinder

PNP Switch Retaining Bolt PNP Switch Retaining Nut Valve Cover Bolt/Nut (2) Vehicle Speed Sensor Retaining Bolt A/T M/T VVT Camshaft Timing Oil Control Valve Retaining Bolt (1) Information is not available from manufacturer.
(2) Tighten to specification in sequence. See Fig. 85 .

48 (5.4) 61 (6.9) 89 (10.1) 62 (7.0) 97 (11.0) 75 (8.5)

TORQUE SPECIFICATIONS (HIGHLANDER) Application A/F Sensor ECT Sensor Fuel Rail-To-Cylinder Head Bolt Heated Oxygen Sensor Intake Manifold Bolt/Nut Knock Sensor Power Steering Pressure Switch Throttle Body Bolt Camshaft Position Sensor Bolt Control Lever Nut Crankshaft Position Sensor Bolt Fuel Pump Retaining Plate-To-Fuel Tank Bolt Ignition Coil Bolt PNP Switch Retaining Bolt PNP Switch Retaining Nut VVT Camshaft Timing Oil Control Valve Retaining Bolt (1) Information is not available from manufacturer. TORQUE SPECIFICATIONS (MR2) Application A/C Compressor Bolt ECT Sensor Fuel Rail-To-Cylinder Head Bolt Heated Oxygen Sensor Intake Manifold Bolt/Nut Knock Sensor Suspension Upper Brace Bolt Suspension Upper Brace Nut Throttle Body Bolt/Nut

Ft. Lbs. (N.m)

(1)

15 (20) 15 (20)
(1)

22 (30) 29 (39) 15 (20) 22 (30) INCH Lbs. (N.m) 80 (9.0) 112 (12.7) 80 (9.0)
(1)

80 (9.0) 48 (5.4) 61 (6.9) 80 (9.0)

Ft. Lbs. (N.m) 18 (24) 15 (20) 14 (19) 32 (43) 22 (30) 29 (39) 54 (73) 59 (80) 22 (30)

2002 ENGINE PERFORMANCE Removal, Overhaul & Installation - 4-Cylinder

Throttle Body Support Bracket Bolt (1) Accelerator Pedal Position Sensor Bolt (1) Camshaft Position Sensor Bolt Crankshaft Position Sensor Bolt Fuel Pump Protector Cover Bolt Fuel Pump Retaining Plate-To-Fuel Tank Bolt Ignition Coil Bolt TP Sensor Retaining Screw (1) VVT Camshaft Timing Oil Control Valve Retaining Bolt (1) Applies only to models with sequential manual transaxle. TORQUE SPECIFICATIONS (PRIUS) Application Accelerator Pedal Retaining Bolt Exhaust Pipe-To-Exhaust Manifold Bolt Fuel Rail-To-Cylinder Head Bolt Fuel Tank Retaining Bolt Heated Oxygen Sensor Intake Manifold Bolt/Nut Knock Sensor Throttle Body Bolt/Nut Crankshaft Position Sensor Bolt Fuel Pipe Clamp-To-Cylinder Head Bolt Ignition Coil Bolt TP Sensor Retaining Screw Valve Cover Bolt/Nut (1) VVT Camshaft Timing Oil Control Valve Retaining Bolt (1) Tighten to specification in sequence. See Fig. 85 . TORQUE SPECIFICATIONS (RAV4) Application A/F Sensor ECT Sensor Fuel Rail-To-Cylinder Head Bolt Heated Oxygen Sensor Intake Manifold Bolt/Nut Knock Sensor Power Steering Pressure Switch Throttle Body Bolt Vehicle Speed Sensor Retaining Bolt

36 (49) INCH Lbs. (N.m) 48 (5.4) 80 (9.0) 80 (9.0) 30 (3.4) 30 (3.4) 80 (9.0) 18 (2.0) 80 (9.0)

Ft. Lbs. (N.m) 12 (16) 46 (62) 14 (19) 29 (39) 32 (43) 15 (20) 32 (43) 15 (20) INCH Lbs. (N.m) 66 (7.5) 80 (9.0) 80 (9.0) 15 (1.7) 89 (10.1) 66 (7.5)

Ft. Lbs. (N.m) 32 (43) 15 (20) 15 (20) 32 (43) 22 (30) 29 (39) 15 (20) 22 (30)

2002 ENGINE PERFORMANCE Removal, Overhaul & Installation - 4-Cylinder

A/T M/T Camshaft Position Sensor Bolt Control Lever Nut Crankshaft Position Sensor Bolt Fuel Pump Retaining Plate-To-Fuel Tank Bolt Ignition Coil Bolt PNP Switch Retaining Bolt PNP Switch Retaining Nut VVT Camshaft Timing Oil Control Valve Retaining Bolt (1) Tighten retaining bolt to 49 INCH lbs. (5.5 N.m). TORQUE SPECIFICATIONS (TACOMA) Application A/F Sensor Retaining Nut ECT Sensor EGR Pipe Bolt/Nut 2.7L 3RZ-FE EGR Valve Retaining Nut 2.7L 3RZ-FE Fuel Filter Mounting Bolt Fuel Inlet Pipe-To-Fuel Rail Union Bolt Fuel Rail-To-Cylinder Head Bolt Generator Mounting Bracket-To-Timing Chain Cover Bolt Large Bolt Small Bolt Heated Oxygen Sensor-To-Exhaust Pipe Retaining Nut Knock Sensor Starter Bolt Throttle Body Bolt/Nut Transmission Oil Cooler Line Elbow Transmission Oil Cooler Line Nut Vehicle Speed Sensor Retaining Bolt Airflow Meter Retaining Nut Camshaft Position Sensor Bolt Crankshaft Position Sensor Bolt Fuel Pressure Regulator Bolt Fuel Pump Mounting Bracket-To-Fuel Tank Bolt Ignition Coil Bolt PNP Switch Retaining Bolt 2.4L 2RZ-FE

(1)

13 (18) INCH Lbs. (N.m) 80 (9.0) 112 (12.7) 80 (9.0) 30 (3.4) 80 (9.0) 48 (5.4) 61 (6.9) 80 (9.0)

Ft. Lbs. (N.m) 15 (20) 15 (20) 14 (19) 14 (19) 15 (20) 22 (30) 15 (20) 55 (75) 13 (18) 15 (20) 33 (45) 29 (39) 15 (20) 25 (34) 25 (34)
(1)

INCH Lbs. (N.m) 75 (8.5) 48 (5.4) 75 (8.5) 78 (8.8) 31 (3.5) 66 (7.5) 48 (5.4)

2002 ENGINE PERFORMANCE Removal, Overhaul & Installation - 4-Cylinder

2.7L 3RZ-FE 115 (13.0) PNP Switch Retaining Nut 2.4L 2RZ-FE 35 (4.0) 2.7L 3RZ-FE 61 (6.9) (1) On A/T models, tighten retaining bolt to 12 ft. lbs. (16 N.m) on 2WD models or 102 INCH lbs. (11.5 N.m) on 4WD models. On M/T models, tighten retaining bolt to 115 INCH. lbs. (13.0 N.m) on 2WD models or 102 INCH lbs. (11.5 N.m) on 4WD models.

2002 ENGINE PERFORMANCE Sensor Operating Range Charts

2002 ENGINE PERFORMANCE Sensor Operating Range Charts

INTRODUCTION
NOTE: Before using sensor operating range information, check for any related Technical Service Bulletins (TSBs).

Sensor operating range information can help determine if a sensor is out of calibration. An out-of-calibration sensor may not set a diagnostic trouble code, but it may cause driveability problems. NOTE: Unless stated otherwise, perform all voltage tests using a Digital VoltOhmmeter (DVOM) with a minimum 10-megohm input impedance.

SERVICE PRECAUTIONS
PRIUS WARNING: When performing any inspection or service procedure on this vehicle, ensure following service precautions are followed to prevent personal injury or death due to the extremely high voltage. The following service precautions must be followed:

Ensure ignition is off and ignition key is removed from ignition before performing any inspection or service procedure in engine compartment, as engine may automatically start and shut off when ignition is on and READY light is illuminated. READY light is displayed just above the shift lever position indicator on instrument cluster at center of instrument panel. Read all service and warning labels in engine compartment before performing any procedures in engine compartment. All high-voltage wiring harness connectors contain Orange connectors. DO NOT touch any wiring harness that contains Orange connectors. High-voltage battery and other high-voltage components may be identified by HIGH VOLTAGE caution labels on them. DO NOT touch these components. If necessary to inspect or service high-voltage system, ensure ignition is off. Remove service plug and wait at least 5 minutes to ensure high voltage is fully discharged before touching any high-voltage wiring harness, connectors or components. Service plug is located on service plug assembly at driver's side front corner of trunk compartment, near high-voltage battery. See Fig. 1 . Ensure service plug is stored in a location in which no one may install service plug while technician is working on the vehicle. If necessary to touch any high-voltage wiring harness, connectors or components, ensure service plug is removed and battery voltage or less exists at electrical connector. Use Toyota insulated gloves when touching any high-voltage wiring harness, connectors or components. Ensure insulated gloves are dry and in good condition. Ensure that no holes exist in insulated gloves. Test by applying air to insulated glove before touching any high-voltage wiring harness, connectors or components. DO NOT wear any metal objects while working on vehicle which may accidently drop and cause a short circuit.

2002 ENGINE PERFORMANCE Sensor Operating Range Charts

If any high-voltage wiring harness connector is disconnected, ensure terminal on wiring harness connector is wrapped with tape to prevent wiring harness connector from contacting any surface. If servicing high-voltage system, place sign on roof of vehicle to indicate to other technicians that high-voltage system is being serviced.

Fig. 1: Locating Service Plug & Service Plug Assembly (Prius)

2002 ENGINE PERFORMANCE Sensor Operating Range Charts

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

SENSOR OPERATING RANGE INFORMATION

ACCELERATOR PEDAL POSITION SENSOR
Camry 2.4L 4-Cylinder & Camry Solara 2.4L 4-Cylinder

For accelerator pedal position sensor testing procedures, see ACCELERATOR PEDAL POSITION SENSOR under ENGINE SENSORS & SWITCHES in SYSTEM & COMPONENT TESTING - 4CYLINDER article.
Camry 3.0L V6

For accelerator pedal position sensor testing procedures, see ACCELERATOR PEDAL POSITION SENSOR under ENGINE SENSORS & SWITCHES in SYSTEM & COMPONENT TESTING - V6 & V8 article.
Land Cruiser, Sequoia, Tundra 4.7L V8 & 4Runner

For accelerator pedal position sensor testing procedures, see THROTTLE BODY under IDLE CONTROL SYSTEMS in SYSTEM & COMPONENT TESTING - V6 & V8 article.
MR2 With Sequential Manual Transaxle

There are 2 types of manual transaxles used. Sequential manual transaxle may be identified by the shift lever pattern which consists of "R", "N", "S" and "+" in place of the conventional type shift lever pattern and there is no clutch pedal. This model uses an accelerator pedal position sensor. For accelerator pedal position sensor testing procedures, see THROTTLE BODY under IDLE CONTROL SYSTEMS in SYSTEM & COMPONENT TESTING - 4-CYLINDER article.
Prius

WARNING: Read service precautions before proceeding with service procedure. See SERVICE PRECAUTIONS . For accelerator pedal position sensor testing procedures, see ACCELERATOR PEDAL POSITION SENSOR under ENGINE SENSORS & SWITCHES in SYSTEM & COMPONENT TESTING - 4CYLINDER article. AIR/FUEL SENSOR NOTE: Air/Fuel (A/F) sensor may also be referred to as Air/Fuel (A/F) ratio sensor.

Avalon, Camry, Camry Solara 2.4L 4-Cylinder, Camry Solara 3.0L V6 With A/T, Highlander, RAV4, Sienna, Tacoma, Tundra 3.4L V6 & 4Runner

For Air/Fuel (A/F) sensor testing procedures, see AIR/FUEL SENSOR under ENGINE SENSORS & SWITCHES in appropriate SYSTEM & COMPONENT TESTING article.

2002 ENGINE PERFORMANCE Sensor Operating Range Charts

AIRFLOW METER NOTE: Airflow meter may be referred to as Mass Airflow (MAF) meter. WARNING: On Prius, read service precautions before proceeding with service procedure. See SERVICE PRECAUTIONS .
All Models

For airflow meter terminal identification and testing procedures, see AIRFLOW METER under ENGINE SENSORS & SWITCHES in appropriate SYSTEM & COMPONENT TESTING article. Ensure resistance is within specification in relation to specified temperature. See AIRFLOW METER RESISTANCE table. AIRFLOW METER RESISTANCE Application & Temperature Avalon -4F (-20C) 68F (20C) 140F (60C) Camry -4F (-20C) 68F (20C) 140F (60C) Camry Solara 2.4L 4-Cyl. -4F (-20C) 68F (20C) 140F (60C) 3.0L V6 -4F (-20C) 68F (20C) 140F (60C) Celica & ECHO -4F (-20C) 68F (20C) 140F (60C) Corolla -4F (-20C) 68F (20C) 140F (60C) Highlander -4F (-20C) 68F (20C) 140F (60C) Land Cruiser

Ohms 13,600-18,400 2210-2690 490-670 13,600-18,400 2210-2690 493-667

13,600-18,400 2210-2690 490-670 14,600-17,800 2210-2690 290-350 13,600-18,400 2210-2690 490-670 13,600-18,400 2200-2700 500-700 13,600-18,400 2210-2690 493-667

2002 ENGINE PERFORMANCE Sensor Operating Range Charts

WARNING: On Prius, read service precautions before proceeding with service procedure. See SERVICE PRECAUTIONS . For camshaft position sensor testing procedures, see CAMSHAFT POSITION SENSOR under IGNITION SYSTEMS in appropriate BASIC DIAGNOSTIC PROCEDURES article. Ensure resistance is within specification. See CAMSHAFT POSITION SENSOR RESISTANCE table. CAMSHAFT POSITION SENSOR RESISTANCE Application Avalon & Camry Cold (1) Hot (2) Camry Solara 2.4L 4-Cyl. Cold (1) Hot (2) 3.0L V6 Denso Sensor (3) Cold (1) Hot (2) Wabash Sensor (3) Cold (1) Hot (2) Celica & Corolla Cold (1) Hot (2) ECHO & Prius Cold (1) Hot (2) Highlander, Land Cruiser, MR2, RAV4, Sequoia, Sienna, Tacoma, Tundra & 4Runner Cold (1) Hot (2) (1) Cold is with temperature of 14-122F (-10-50C).
(2) Hot is with temperature of 122-212F (50-100C). (3) This is manufacturer of camshaft position sensor.

Ohms 835-1400 1060-1645

835-1400 1060-1645

835-1400 1060-1645 1690-2560 2145-3010 835-1400 1060-1645 1630-2740 2065-3225 835-1400 1060-1645

CRANKSHAFT POSITION SENSOR

All Models

WARNING: On Prius, read service precautions before proceeding with service

2002 ENGINE PERFORMANCE Sensor Operating Range Charts

procedure. See SERVICE PRECAUTIONS . For crankshaft position sensor testing procedures, see CRANKSHAFT POSITION SENSOR under IGNITION SYSTEMS in appropriate BASIC DIAGNOSTIC PROCEDURES article. Ensure resistance is within specification. See CRANKSHAFT POSITION SENSOR RESISTANCE table. CRANKSHAFT POSITION SENSOR RESISTANCE Application Avalon Cold (1) Hot (2) Camry & Camry Solara 2.4L 4-Cyl. Cold (1) Hot (2) 3.0L V6 Cold (1) Hot (2) Celica & Corolla Cold (1) Hot (2) ECHO Cold (1) Hot (2) Highlander 2.4L 4-Cyl. Cold (1) Hot (2) 3.0L V6 Cold (1) Hot (2) Land Cruiser & MR2 Cold (1) Hot (2) Prius & RAV4 Cold (1) Hot (2) Sequoia, Sienna, Tacoma, Tundra & 4Runner Cold (1) Hot (2) Cold is with temperature of 14-122F (-10-50C). 1630-2740 2065-3225 985-1600 1265-1890 1630-2740 2065-3225 985-1600 1265-1890 1630-2740 2065-3225 985-1600 1265-1890 1630-2740 2065-3225

Ohms 1630-2740 2065-3225

985-1600 1265-1890 1630-2740 2065-3225

2002 ENGINE PERFORMANCE Sensor Operating Range Charts

(1) (2) Hot is with temperature of 122-212F (50-100C).

EGR GAS TEMPERATURE SENSOR

Camry 3.0L V6, Camry Solara 3.0L V6 & Tacoma 2.7L 4-Cylinder 3RZ-FE

For EGR gas temperature sensor testing procedures, see EGR GAS TEMPERATURE SENSOR under ENGINE SENSORS & SWITCHES in appropriate SYSTEM & COMPONENT TESTING article. Ensure resistance is within specification in relation to specified temperature. See EGR GAS TEMPERATURE SENSOR RESISTANCE table. EGR GAS TEMPERATURE SENSOR RESISTANCE Application & Temperature Camry 122F (50C) 212F (100C) 302F (150C) Camry Solara & Tacoma 122F (50C) 212F (100C) 302F (150C) EGR POSITION SENSOR
Camry 3.0L V6 & Camry Solara 3.0L V6

Ohms 69,400-88,500 11,890-14,370 2790-3590 64,000-97,000 11,000-16,000 2000-4000

For EGR position sensor testing procedures, see EGR POSITION SENSOR (CAMRY & CAMRY SOLARA) under EMISSION SYSTEMS & SUB-SYSTEMS in SYSTEM & COMPONENT TESTING V6 & V8 article. ENGINE COOLANT TEMPERATURE SENSOR
All Models

WARNING: On Prius, read service precautions before proceeding with service procedure. See SERVICE PRECAUTIONS . For Engine Coolant Temperature (ECT) sensor location and testing procedures, see ENGINE COOLANT TEMPERATURE SENSOR under ENGINE SENSORS & SWITCHES in appropriate SYSTEM & COMPONENT TESTING article. Ensure resistance is within specification in relation to specified temperature. See Fig. 2 .

2002 ENGINE PERFORMANCE Sensor Operating Range Charts

Fig. 2: Testing Engine Coolant Temperature Sensor Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 ENGINE PERFORMANCE Sensor Operating Range Charts

HEATED OXYGEN SENSOR

All Models

WARNING: On Prius, read service precautions before proceeding with service procedure. See SERVICE PRECAUTIONS . For heated oxygen sensor application and sensor testing procedures, see HEATED OXYGEN SENSOR under ENGINE SENSORS & SWITCHES in appropriate SYSTEM & COMPONENT TESTING article. INTAKE AIR TEMPERATURE SENSOR
All Models

WARNING: On Prius, read service precautions before proceeding with service procedure. See SERVICE PRECAUTIONS . Intake air temperature sensor is incorporated in to airflow meter. For testing procedures, see AIRFLOW METER under ENGINE SENSORS & SWITCHES in appropriate SYSTEM & COMPONENT TESTING article. KNOCK SENSOR
All Models

WARNING: On Prius, read service precautions before proceeding with service procedure. See SERVICE PRECAUTIONS . For knock sensor testing procedures, see KNOCK SENSOR under ENGINE SENSORS & SWITCHES in appropriate SYSTEM & COMPONENT TESTING article. POWER STEERING PRESSURE SENSOR NOTE: Power steering pressure sensor may also be referred to as power steering oil pressure sensor.

ECHO

Power steering pressure sensor is located on side of power steering pump. Testing information is not available from manufacturer. THROTTLE POSITION SENSOR
All Models

For Throttle Position (TP) sensor terminal identification and testing procedures, see THROTTLE POSITION SENSOR under ENGINE SENSORS & SWITCHES in appropriate SYSTEM & COMPONENT TESTING article.

2002 ENGINE PERFORMANCE Sensor Operating Range Charts

VACUUM SENSOR FOR HYDROCARBON ADSORBER CATALYST SYSTEM

Prius

WARNING: Read service precautions before proceeding with service procedure. See SERVICE PRECAUTIONS . For vacuum sensor testing procedures, seVACUUM SENSOR FOR HYDROCARBON ADSORBER CATALYST SYSTEM under ENGINE SENSORS & SWITCHES in SYSTEM & COMPONENT TESTING - 4-CYLINDER article. VAPOR PRESSURE SENSOR
All Models

WARNING: On Prius, read service precautions before proceeding with service procedure. See SERVICE PRECAUTIONS . For vapor pressure sensor testing procedures, see VAPOR PRESSURE SENSOR under FUEL EVAPORATIVE SYSTEM under EMISSION SYSTEMS & SUB-SYSTEMS in appropriate SYSTEM & COMPONENT TESTING article. VARIABLE VALVE TIMING SENSOR NOTE: Variable Valve Timing (VVT) sensor may also be referred to as camshaft position sensor. WARNING: On Prius, read service precautions before proceeding with service procedure. See SERVICE PRECAUTIONS .
Avalon, Camry 2.4L 4-Cylinder, Camry Solara 2.4L 4-Cylinder, Celica, Corolla, ECHO, Highlander, MR2, Prius, RAV4 & Sienna

For Variable Valve Timing (VVT) sensor testing procedures, see CAMSHAFT POSITION SENSOR under IGNITION SYSTEMS in appropriate BASIC DIAGNOSTIC PROCEDURES article. VEHICLE SPEED SENSOR
Camry 2.4L 4-Cylinder, Camry Solara, Celica, Corolla, ECHO, Tacoma, Land Cruiser, Sequoia & Tundra

For vehicle speed sensor testing procedures, see VEHICLE SPEED SENSOR under ENGINE SENSORS & SWITCHES in appropriate SYSTEM & COMPONENT TESTING article.

ENGINE PERFORMANCE Firing Order & Cylinder Identification - Toyota, Lexus & Scion

ENGINE PERFORMANCE Firing Order & Cylinder Identification - Toyota, Lexus & Scion

FIRING ORDER & CYLINDER IDENTIFICATION

Engine Configuation In-Line 4 In-Line 6 Firing Order 1-3-4-2 1-5-3-6-2-4 Cylinder Identifiaction

V6

1-2-3-4-5-6

V8

5.7L

1-8-7-3-6-5-4-2

All Others

1-8-4-3-6-5-7-2

2002 ENGINE PERFORMANCE Service & Adjustment Specifications

2002 ENGINE PERFORMANCE Service & Adjustment Specifications

INTRODUCTION
NOTE: Before using service and adjustment specifications, check for any related Technical Service Bulletins (TSBs). References to California models apply to California emission vehicles, which may be verified by underhood Emission Control label. California emissions may be available in other states.

NOTE:

Use this article to quickly find specifications related to servicing and on-vehicle adjustments. This is a quick-reference article to use when you are familiar with an adjustment procedure and only need a specification.

SERVICE PRECAUTIONS
PRIUS WARNING: When performing any inspection or service procedure on this vehicle, ensure following service precautions are followed to prevent personal injury or death due to the extremely high voltage. The following service precautions must be followed:

Ensure ignition is off and ignition key is removed from ignition before performing any inspection or service procedure in engine compartment, as engine may automatically start and shut off when ignition is on and READY light is illuminated. READY light is displayed just above the shift lever position indicator on instrument cluster at center of instrument panel. Read all service and warning labels in engine compartment before performing any procedures in engine compartment. All high-voltage wiring harness connectors contain Orange connectors. DO NOT touch any wiring harness that contains Orange connectors. High-voltage battery and other high-voltage components may be identified by HIGH VOLTAGE caution labels on them. DO NOT touch these components. If necessary to inspect or service high-voltage system, ensure ignition is off. Remove service plug and wait at least 5 minutes to ensure high voltage is fully discharged before touching any high-voltage wiring harness, connectors or components. Service plug is located on service plug assembly at driver's side front corner of trunk compartment, near high-voltage battery. For illustration of service plug location, See SERVICE PRECAUTIONS in ON-VEHICLE ADJUSTMENTS - 4-CYLINDER article. Ensure service plug is stored in a location in which no one may install service plug while technician is working on the vehicle. If necessary to touch any high-voltage wiring harness, connectors or components, ensure service plug is removed and battery voltage or less exists at electrical connector. Use Toyota insulated gloves when touching any high-voltage wiring harness, connectors or components. Ensure insulated gloves are dry and in good condition and that no holes exist in insulated gloves. Test by applying air pressure to

2002 ENGINE PERFORMANCE Service & Adjustment Specifications

(4) Use SAE 80W or 80W-90 gear oil in temperatures less than 0F (-18C), or SAE 90 gear oil in

temperatures of 0F (-18C) or more.

QUICK-SERVICE
WARNING: On Prius, read service precautions before proceeding with service procedure. See SERVICE PRECAUTIONS . REPLACEMENT INTERVALS (AVALON, CAMRY, CAMRY SOLARA, CELICA, COROLLA, ECHO, MR2, PRIUS & SIENNA) Component Months Miles A/C Air Filter (1) Avalon & Camry (2) Normal Service Severe Service Air Filter Automatic Transaxle Fluid (2) (3) Avalon, Camry, Camry Solara, Corolla & Sienna Normal Service Severe Service Celica & ECHO Normal Service Severe Service Coolant Engine Oil & Filter (2) Normal Service Severe Service Manual Transaxle Fluid Normal Service Severe Service Spark Plugs Avalon, Camry, Camry 2.4L 4-Cyl., Celica, Corolla, MR2 & Prius Camry Solara 3.0L V6 ECHO Sienna Timing Belt (6) Avalon, Camry 3.0L V6, Camry Solara 3.0L V6 & Sienna 12 8 24 15,000 10,000 30,000

(4) (5) (4)

(4) (5) (4)

48 24 6 4
(4)

60,000 30,000 7500 5000

(4)

24 96 48 24 48 72

30,000 120,000 60,000 30,000 60,000 90,000

48 60,000 Valve Clearance (7) (1) A/C air filter may also be referred to as cabin air filter. A/C air filter is located behind glove box, in filter case assembly, just above blower motor assembly.

2002 ENGINE PERFORMANCE Service & Adjustment Specifications

(2) Different interval is required for normal service and severe service. Severe service is described as

using cartop carrier, trailer towing, operating for short trips of less than 5 miles in freezing temperatures, extensive idling or low speed driving for long distances, or operating in rough, muddy or dusty conditions. (3) If transaxle has separate differential fluid reservoir on the transaxle, change differential fluid when changing transaxle fluid. (4) Service interval is not available from manufacturer.
(5) Inspect fluid every 12 months or 15,000 miles. Replace fluid every 24 months or 30,000 miles. (6) Timing belt used only on models listed. All other models use timing chain. (7) Manufacturer recommends listening for valve noise from excessive valve clearance. Adjust valve

clearance if valve noise exists. REPLACEMENT INTERVALS (HIGHLANDER, LAND CRUISER, RAV4, SEQUOIA, TACOMA, TUNDRA & 4RUNNER) Component Months Miles A/C Filter (1) Highlander & RAV4 (2) Normal Service Severe Service Air Filter Automatic Transaxle/Transmission Fluid (2) Highlander & RAV4 Normal Service Severe Service Land Cruiser, Sequoia, Tacoma, Tundra & 4Runner Normal Service Severe Service Coolant Engine Oil & Filter (2) Normal Service Severe Service Front Differential Fluid (4WD) (2) Land Cruiser, Sequoia, Tacoma, Tundra & 4Runner Normal Service Severe Service Manual Transaxle/Transmission Fluid (2) RAV4, Tacoma & Tundra Normal Service Severe Service Rear Differential Fluid (2) Highlander & RAV4
(3) (3)

18 8 24

22,500 10,000 30,000

(3)

(3)

48
(3) (4)

60,000
(3) (4)

24 6 4

30,000 7500 5000

(3)

(3)

12

15,000

24

30,000

2002 ENGINE PERFORMANCE Service & Adjustment Specifications

(4) Inspect fluid every 12 months or 15,000 miles. Replace fluid every 24 months or 30,000 miles. (5) Timing belt used only on models listed. All other models use timing chain. (6) Manufacturer recommends listening for valve noise from excessive valve clearance. Adjust valve

clearance if valve noise exists. BELT ADJUSTMENT - Tension In Lbs. (kg) Using Belt Tension Gauge (4-CYLINDER) Application Camry & Camry Solara Drive Belt Celica & Corolla Drive Belt ECHO A/C Generator Power Steering Highlander & MR2 Drive Belt Prius (3) A/C Water Pump RAV4 Drive Belt Tacoma A/C Generator Power Steering (1) Used belt is a belt in operation at least 5 minutes. New Belt
(2) (2) (1) Used Belt (2) (2)

110-154 (50-70) 121-143 (55-65) 100-121 (45-55)

(2)

77-100 (35-45) 55-88 (25-40) 55-77 (25-35)

(2)

99-121 (44-55) 99-121 (44-55)

(2)

57-77 (26-35) 57-77 (26-35)

(2)

135-185 (61-84) 116-169 (53-76) 135-180 (61-82)

80-120 (36-54) 66-88 (30-40) 85-120 (39-54)

(2) Automatic belt tensioner is used. Adjustment is not required. (3) Read service precautions before proceeding with service procedure. See SERVICE

PRECAUTIONS . BELT ADJUSTMENT - Tension In Lbs. (kg) Using Belt Tension Gauge (V6) Application Avalon A/C Generator Power Steering Camry A/C Generator Power Steering New Belt 143-187 (65-85) 170-180 (77-82) 120-185 (54-84) 138-192 (63-87) 138-192 (63-87) 146-190 (66-86)
(1) Used Belt

66-110 (30-50) 95-135 (43-61) 95-135 (43-61) 66-110 (30-50) 66-110 (30-50) 73-117 (33-53)

2002 ENGINE PERFORMANCE Service & Adjustment Specifications

Fig. 1: Locating Arrow Mark On Automatic Belt Tensioner (Land Cruiser, Sequoia & Tundra 4.7L) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

MECHANICAL CHECKS
ENGINE COMPRESSION Check engine compression with engine at cranking speed with battery fully charged, engine at normal operating temperature, electrical connector disconnected at ignition coil if ignition coil is not removed for access to spark plugs, all spark plugs removed and throttle wide open. WARNING: On Prius, read service precautions before proceeding with service procedure. See SERVICE PRECAUTIONS . NOTE: On Prius, when checking engine compression, connect Toyota hand-held tester to data link connector No. 3 located below driver's side of instrument panel and follow scan tool instructions to select cranking mode. This will

2002 ENGINE PERFORMANCE Service & Adjustment Specifications

automatically set cranking speed to 250 RPM and set throttle at wide open position. ENGINE COMPRESSION SPECIFICATIONS (4-CYLINDER) Application Normal Compression Pressure Camry & Camry Solara Celica 1.8L (1ZZ-FE) 1.8L (2ZZ-GE) Corolla ECHO Highlander MR2 Prius (1) RAV4 Tacoma Minimum Compression Pressure Camry & Camry Solara Celica 1.8L (1ZZ-FE) & 1.8L (2ZZ-GE) Corolla ECHO Highlander MR2 Prius RAV4 Tacoma Maximum Variation Between Cylinders Camry & Camry Solara Celica 1.8L (1ZZ-FE) 1.8L (2ZZ-GE) Corolla, ECHO, Highlander, MR2, Prius, RAV4 & Tacoma

Specification 198 psi (13.9 kg/cm2 ) 218 psi (15.3 kg/cm2 ) 203 psi (14.3 kg/cm2 ) 218 psi (15.3 kg/cm2 ) 213 psi (15.0 kg/cm2 ) 198 psi (13.9 kg/cm2 ) 184 psi (13.0 kg/cm2 ) 106 psi (7.4 kg/cm2 ) 184 psi (13.0 kg/cm2 ) 178 psi (12.5 kg/cm2 ) 142 psi (10.0 kg/cm2 ) 145 psi (10.2 kg/cm2 ) 145 psi (10.2 kg/cm2 ) 156 psi (11.0 kg/cm2 ) 142 psi (10.0 kg/cm2 ) 145 psi (10.2 kg/cm2 ) 77 psi (5.4 kg/cm2 ) 145 psi (10.2 kg/cm2 ) 128 psi (9.0 kg/cm2 ) 14 psi (1.0 kg/cm2 ) 14 psi (1.0 kg/cm2 ) 16 psi (1.1 kg/cm2 )

14 psi (1.0 kg/cm2 ) (1) Read service precautions before proceeding with service procedure. See SERVICE PRECAUTIONS . ENGINE COMPRESSION SPECIFICATIONS (V6) Application Normal Compression Pressure

Specification

2002 ENGINE PERFORMANCE Service & Adjustment Specifications

Avalon Camry Camry Solara Highlander Sienna Tacoma, Tundra & 4Runner Minimum Compression Pressure Avalon Camry Camry Solara Highlander Sienna, Tacoma, Tundra & 4Runner Maximum Variation Between Cylinders All Models ENGINE COMPRESSION SPECIFICATIONS (V8) Application Normal Compression Pressure Land Cruiser, Sequoia & Tundra Minimum Compression Pressure Land Cruiser, Sequoia & Tundra Maximum Variation Between Cylinders Land Cruiser, Sequoia & Tundra VALVE CLEARANCE

218 psi (15.3 kg/cm2 ) 213 psi (15.0 kg/cm2 ) 218 psi (15.3 kg/cm2 ) 213 psi (15.0 kg/cm2 ) 218 psi (15.3 kg/cm2 ) 174 psi (12.2 kg/cm2 ) 145 psi (10.2 kg/cm2 ) 142 psi (10.0 kg/cm2 ) 145 psi (10.2 kg/cm2 ) 142 psi (10.0 kg/cm2 ) 145 psi (10.2 kg/cm2 ) 14 psi (1.0 kg/cm2 )

Specification 192 psi (13.5 kg/cm2 ) 142 psi (10.0 kg/cm2 ) 14 psi (1.0 kg/cm2 )

WARNING: On Prius, read service precautions before proceeding with service procedure. See SERVICE PRECAUTIONS . VALVE CLEARANCE SPECIFICATIONS (4-CYLINDER) (1) Application Camry & Camry Solara Intake Exhaust Celica 1.8L (1ZZ-FE) Intake Exhaust 1.8L (2ZZ-GE) Intake Exhaust

In. (mm) .007-.011 (.19-.29) .012-.016 (.30-.40)

.006-.010 (.15-.25) .010-.014 (.25-.35) .003-.007 (.08-.19) .008-.013 (.22-.33)

2002 ENGINE PERFORMANCE Service & Adjustment Specifications

Corolla & ECHO Intake Exhaust Highlander Intake Exhaust MR2 Intake Exhaust

.006-.010 (.15-.25) .010-.014 (.25-.35) .007-.011 (.19-.29) .012-.016 (.30-.40) .006-.010 (.15-.25) .010-.014 (.25-.35)

Prius (2) Intake .006-.010 (.15-.25) Exhaust .010-.014 (.25-.35) RAV4 Intake .007-.011 (.19-.29) Exhaust .012-.016 (.30-.40) Tacoma Intake .006-.010 (.15-.25) Exhaust .010-.014 (.25-.35) (1) Adjust valve clearance with engine cold. Verify valve clearance listed with valve clearance listed on underhood label (if available). If valve clearance on underhood label differs from valve clearance listed, use specification on underhood label. (2) Read service precautions before proceeding with service procedure. See SERVICE PRECAUTIONS . VALVE CLEARANCE SPECIFICATIONS (V6) (1) Application In. (mm) Avalon, Camry, Camry Solara, Highlander & Sienna Intake .006-.010 (.15-.25) Exhaust .010-.014 (.25-.35) Tacoma, Tundra & 4Runner Intake .006-.009 (.15-.23) Exhaust .011-.014 (.29-.35) (1) Adjust valve clearance with engine cold. Verify valve clearance listed with valve clearance listed on underhood label (if available). If valve clearance on underhood label differs from valve clearance listed, use specification on underhood label. VALVE CLEARANCE SPECIFICATIONS (V8) (1) Application In. (mm) Land Cruiser, Sequoia & Tundra Intake .006-.010 (.15-.25) Exhaust .010-.014 (.25-.35) (1) Adjust valve clearance with engine cold. Verify valve clearance listed with valve clearance listed on underhood label (if available). If valve clearance on underhood label differs from valve

2002 ENGINE PERFORMANCE Service & Adjustment Specifications

clearance listed, use specification on underhood label.

IGNITION SYSTEMS
IGNITION COIL IGNITION COIL RESISTANCE - Ohms (4-CYLINDER) Application Primary (1) Camry, Camry Solara, Celica, Corolla, ECHO, Highlander & MR2 Prius (2) RAV4 & Tacoma
(1) Ignition coil resistance is not available from manufacturer. (2) Read service precautions before proceeding with service procedure. See SERVICE (1) (1)

Secondary
(1) (1) (1)

PRECAUTIONS . IGNITION COIL RESISTANCE - Ohms (V6) Application Avalon & Camry Camry Solara Aisan Ign. Coil (2) Cold (3) Hot (4) Diamond Ign. Coil (2) Cold (3) Hot (4) Highlander & Sienna Tacoma, Tundra & 4Runner Cold (3) .67-1.05 9300-16,000 11,700-18,800 .85-1.23 Hot (4) (1) Ignition coil resistance is not available from manufacturer.
(2) This is manufacturer of ignition coil. (3) Cold is with temperature of 14-122F (-10-50C). (4) Hot is with temperature of 122-212F (50-100C).

Primary
(1)

Secondary
(1)

.70-.94 .85-1.10 .70-.94 .85-1.10

(1)

10,800-14,900 13,100-17,500 6800-11,700 8600-13,700

(1)

IGNITION COIL RESISTANCE - Ohms (V8) Application Land Cruiser, Sequoia & Tundra
(1) Ignition coil resistance is not available from manufacturer.

Primary
(1)

Secondary
(1)

2002 ENGINE PERFORMANCE Service & Adjustment Specifications

CAMSHAFT POSITION SENSOR CAMSHAFT POSITION SENSOR RESISTANCE Application Avalon Cold (1) Hot (2) Camry 2.4L 4-Cyl. & 3.0L V6 Cold (1) Hot (2) Camry Solara 2.4L 4-Cyl. Cold (1) Hot (2) 3.0L V6 Denso Sensor (3) Cold (1) Hot (2) Wabash Sensor (3) Cold (1) Hot (2) Celica & Corolla Cold (1) Hot (2) ECHO Cold (1) Hot (2) Highlander, Land Cruiser & MR2 Cold (1) Hot (2) Prius (4) Cold (1) Hot (2) RAV4, Sequoia, Sienna, Tacoma, Tundra & 4Runner Cold (1) Hot (2) (1) Cold is with temperature of 14-122F (-10-50C).
(2) Hot is with temperature of 122-212F (50-100C).

Ohms 835-1400 1060-1645

835-1400 1060-1645

835-1400 1060-1645

835-1400 1060-1645 1690-2560 2145-3010 835-1400 1060-1645 1630-2740 2065-3225 835-1400 1060-1645 1630-2740 2065-3225 835-1400 1060-1645

2002 ENGINE PERFORMANCE Service & Adjustment Specifications

(3) This is manufacturer of camshaft position sensor. (4) Read service precautions before proceeding with service procedure. See SERVICE

PRECAUTIONS . CRANKSHAFT POSITION SENSOR CRANKSHAFT POSITION SENSOR RESISTANCE Application Avalon Cold (1) Hot (2) Camry & Camry Solara 2.4L 4-Cyl. Cold (1) Hot (2) 3.0L V6 Cold (1) Hot (2) Celica & Corolla Cold (1) Hot (2) ECHO Cold (1) Hot (2) Highlander 2.4L 4-Cyl. Cold (1) Hot (2) 3.0L V6 Cold (1) Hot (2) Land Cruiser & MR2 Cold (1) Hot (2) Prius (3) Cold (1) Hot (2) RAV4 Cold (1) Hot (2) 985-1600 1265-1890 985-1600 1265-1890

Ohms 1630-2740 2065-3225

985-1600 1265-1890 1630-2740 2065-3225 1630-2740 2065-3225 985-1600 1265-1890

985-1600 1265-1890 1630-2740 2065-3225 1630-2740 2065-3225

2002 ENGINE PERFORMANCE Service & Adjustment Specifications

Sequoia, Sienna, Tacoma, Tundra & 4Runner Cold (1) Hot (2) (1) Cold is with temperature of 14-122F (-10-50C).
(2) Hot is with temperature of 122-212F (50-100C). (3) Read service precautions before proceeding with service procedure. See SERVICE

1630-2740 2065-3225

PRECAUTIONS . HIGH TENSION WIRE RESISTANCE HIGH TENSION WIRE RESISTANCE Application Maximum Ohms (1) Avalon, Camry, Camry Solara 2.4L 4-Cylinder, Celica, Corolla, ECHO, Highlander, Land Cruiser, MR2, Prius, RAV4, Sequoia, Sienna, Tacoma 2.4L 4-Cyl. & 2.7L 4-Cyl., & Tundra 4.7L V8 Camry Solara 3.0L V6, Tacoma 3.4L V6, Tundra 3.4L V6 & 25,000 Per Wire 4Runner (1) Distributorless Ignition System (DIS) is used with ignition coil mounted on the spark plug. No high tension wires are used. SPARK PLUGS SPARK PLUG TYPE (4-CYLINDER) Application Camry & Camry Solara Celica 1.8L (1ZZ-FE) 1.8L (2ZZ-GE) Corolla ECHO Highlander MR2

NGK No. IFR6A11 IFR5A11 IFR6A11 IFR5A11 BKR5EYA IFR6A11 IFR5A11 IFR5A11

Denso No. SK20R11 SK16R11 SK20R11 SK16R11 K16R-U SK20R11 SK16R11 SK16R11 SK20R11 K16R-U11

Prius (1) RAV4 IFR6A11 Tacoma BKR5EYA-11 (1) Read service precautions before proceeding with service procedure. See SERVICE PRECAUTIONS. SPARK PLUG TYPE (V6) Application Avalon & Camry Camry Solara Highlander & Sienna

NGK No. IFR6A11 BKR6EKPB11 IFR6A11

Denso No. SK20R11 PK20TR11 SK20R11

2002 ENGINE PERFORMANCE Service & Adjustment Specifications

Tacoma, Tundra & 4Runner SPARK PLUG TYPE (V8) Application Land Cruiser Sequoia & Tundra

BKR5EKB-11

K16TR11

NGK No. IFR6A11 BKR6EYA

Denso No. SK20R11 K20R-U

SPARK PLUG SPECIFICATIONS (4-CYLINDER) Application Gap In. (mm) Camry & Camry Solara .043 (1.10) (1) Celica & Corolla ECHO Highlander MR2 Prius (2) RAV4 .043 (1.10) (1) .031 (.80) .043 (1.10) (1) .043 (1.10) (1) .043 (1.10) (1)

Torque Ft. Lbs. (N.m) 14 (19) 13 (18) 13 (18) 14 (19) 19 (26) 13 (18)

14 (19) .043 (1.10) (1) Tacoma .043 (1.10) 15 (20) (1) Engine is equipped with irridium-tipped spark plugs. DO NOT attempt to adjust spark plug gap.
(2) Read service precautions before proceeding with service procedure. See SERVICE

PRECAUTIONS. SPARK PLUG SPECIFICATIONS (V6) Application Avalon & Camry Camry Solara Highlander & Sienna Tacoma, Tundra & 4Runner

Gap In. (mm) .043 (1.10) (1) .043 (1.10) (2) .043 (1.10) (1)

Torque Ft. Lbs. (N.m) 13 (18) 13 (18) 13 (18)

13 (18) .043 (1.10) (2) (1) Engine is equipped with irridium-tipped spark plugs. DO NOT attempt to adjust spark plug gap.
(2) Engine is equipped with twin ground electrode patinum-tipped spark plugs. DO NOT attempt to

adjust spark plug gap. SPARK PLUG SPECIFICATIONS (V8) Application Gap In. (mm) Land Cruiser .043 (1.10) (1)

Torque Ft. Lbs. (N.m) 13 (18)

Sequoia & Tundra .031 (.80) 13 (18) (1) Engine is equipped with irridium-tipped spark plugs. DO NOT attempt to adjust spark plug gap. FIRING ORDER & TIMING MARKS FIRING ORDER Application

Firing Order

2002 ENGINE PERFORMANCE Service & Adjustment Specifications

4-Cylinder (1) Camry & Camry Solara Celica, Corolla, ECHO, Highlander, MR2, Prius, RAV4 & Tacoma V6 (4) Avalon Camry Camry Solara Highlander Sienna Tacoma, Tundra & 4Runner V8 (8) Land Cruiser, Sequoia & Tundra

(2) (3) 1-3-4-2 (2) (3) 1-3-4-2 (5) 1-2-3-4-5-6 (6) 1-2-3-4-5-6 (5) 1-2-3-4-5-6 (5) 1-2-3-4-5 (5) 1-2-3-4-5-6 (7) 1-2-3-4-5-6 (2) Fig. 4 1-8-4-3-6-5-7-

2
(1) Cylinder No. 1 is located at timing chain end of engine. Cylinder No. 4 is located at flywheel end

of engine. (2) System uses a Distributorless Ignition System (DIS) with ignition coil on spark plug for each cylinder. (3) See Fig. 2 .
(4) Cylinder No. 1 is front cylinder on right side of engine when viewed from flywheel end of engine.

Cylinder No. 2 is front cylinder on left side of engine when viewed from flywheel end of engine. Cylinders No. 1, 3 and 5 are on right side of engine. Cylinders No. 2, 4 and 6 are on left side of engine. (5) System uses a Distributorless Ignition System (DIS) with 3 ignition coils. Two cylinders fire simultaneously using same ignition coil. See Fig. 3 . (6) See Fig. 5 .
(7) System uses a Distributorless Ignition System (DIS) with 3 ignition coils. Two cylinders fire

simultaneously using same ignition coil. See Fig. 6 . (8) Cylinder No. 1 is front cylinder on left side of engine when viewed from flywheel end of engine. Cylinder No. 2 is front cylinder on right side of engine when viewed from flywheel end of engine. Cylinders No. 1, 3, 5 and 7 are on left side of engine. Cylinders No. 2, 4, 6 and 8 on right side of engine.

2002 ENGINE PERFORMANCE Service & Adjustment Specifications

Fig. 2: Identifying Cylinder Numbering & Firing Order (4-Cylinder) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 3: Identifying Cylinder Numbering & Firing Order (Avalon 3.0L, Highlander 3.0L & Sienna

2002 ENGINE PERFORMANCE Service & Adjustment Specifications

3.0L) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 4: Identifying Cylinder Numbering & Firing Order (4.7L) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 ENGINE PERFORMANCE Service & Adjustment Specifications

IGNITION TIMING NOTE: All models, timing marks are located on crankshaft pulley and front cover. WARNING: On Prius, read service precautions before proceeding with service procedure. See SERVICE PRECAUTIONS . IGNITION TIMING (Degrees BTDC @ Idle) (4-CYLINDER) (1) Application Camry & Camry Solara Celica 1.8L (1ZZ-FE) 1.8L (2ZZ-GE) Corolla ECHO Highlander MR2 Prius (7) RAV4 Tacoma Base Timing
(2) 8-12 (2) 10-18 (2) 8-12 (5) 8-12 (2) 8-12 (2) 8-12 (2) 8-12 (2) 7-15 (2) 8-12 (2) 3-7

ECM Controlled Timing

(3) 5-15 (4) (4) (6) 6-15 (4) (3) 5-15 (3) 6-15 (4) (3) 5-15 (3) 4-17

(1) Check with engine at normal operating temperature, transaxle/transmission in Neutral (except

Prius, in Park on Prius), parking brake applied, and A/C and all accessories off. (2) With Jumper Wire (SST 09843-18020 or SST 09843-18040) installed between terminals No. 4 (CG) and 13 (TC) on data link connector No. 3. (3) With jumper wire removed from data link connector No. 3.
(4) Information is not available from manufacturer. (5) With Jumper Wire (SST 09843-18020 or SST 09843-18040) installed between terminals TE1 and

E1 on data link connector No. 1. (6) With jumper wire removed from data link connector No. 1.
(7) Read service precautions before proceeding with service procedure. See SERVICE

PRECAUTIONS . Check with transit in inspection mode and transaxle in Park. IGNITION TIMING (Degrees BTDC @ Idle) (V6) (1) Application Base Timing (2) 8-12 Avalon Camry Camry Solara Highlander Sienna
(4) 8-12 (6) 8-12 (4) 8-12 (6) 8-12

ECM Controlled Timing

(3) 10-25 (5) 7-25 (3) 7-24 (5) 7-24 (3) 7-24

2002 ENGINE PERFORMANCE Service & Adjustment Specifications

Tacoma Tundra 4Runner

(4) 8-12 (4) 8-12 (6) 8-12

(5) 3-19 (5) 12.5-22 (3) 3-19

(1) Check with engine at normal operating temperature, transaxle/transmission in Neutral, parking

brake applied, and A/C and all accessories off. (2) With Jumper Wire (SST 09843-18020 or SST 09843-18040) installed between terminals TE1 and E1 on data link connector No. 1. (3) With jumper wire removed from data link connector No. 1.
(4) With Jumper Wire (SST 09843-18020 or SST 09843-18040) installed between terminals CG and

TC on data link connector No. 3. (5) With jumper wire removed from data link connector No. 3.
(6) With Jumper Wire (SST 09843-18020 or SST 09843-18040) installed between terminals E1 and

TC on data link connector No. 1. IGNITION TIMING (Degrees BTDC @ Idle) (V8) (1) Application Base Timing (2) 5-15 Land Cruiser Sequoia Tundra
(5) 5-15 (5) 8-12

ECM Controlled Timing

(3) (4) (4) (6) (4) (6)

(1) Check with engine at normal operating temperature, transmission in Neutral, parking brake

applied, and A/C and all accessories off. (2) With Jumper Wire (SST 09843-18020 or SST 09843-18040) installed between terminals TC and E1 on data link connector No. 1. (3) With jumper wire removed from data link connector No. 1.
(4) Information was not available from manufacturer. (5) With Jumper Wire (SST 09843-18020 or SST 09843-18040) installed between terminals CG and

TC on data link connector No. 3. (6) With jumper wire removed from data link connector No. 3.

FUEL SYSTEMS
FUEL PUMP NOTE: Fuel pump performance measures fuel pressure, not regulated fuel pressure.

FUEL PUMP PERFORMANCE (4-CYLINDER) Application Camry, Camry Solara, Celica, Corolla, ECHO, Highlander & MR2 Prius (2) RAV4
(1) Pressure psi (kg/cm2 )

44-50 (3.1-3.5) 44-50 (3.1-3.5) 44-50 (3.1-3.5)

2002 ENGINE PERFORMANCE Service & Adjustment Specifications

Tacoma 38-44 (2.7-3.1) (1) Check fuel pressure with engine off and using Toyota hand-held tester connected to data link connector No. 3 with ignition on to activate fuel pump or by connecting battery voltage to terminals on electric fuel pump. (2) Read service precautions before proceeding with service procedure. See SERVICE PRECAUTIONS . FUEL PUMP PERFORMANCE (V6)
(1) Pressure psi (kg/cm2 ) Application Avalon, Camry, Camry Solara, Highlander & 44-50 (3.1-3.5) Sienna Tacoma, Tundra & 4Runner 38-44 (2.7-3.1) (1) Check fuel pressure with engine off and using Toyota hand-held tester connected to data link connector No. 3 with ignition on to activate fuel pump or by connecting battery voltage to terminals on electric fuel pump.

FUEL PUMP PERFORMANCE (V8)

(1) Pressure psi (kg/cm2 ) Application Land Cruiser, Sequoia & Tundra 38-44 (2.7-3.1) (1) Check fuel pressure with engine off and using Toyota hand-held tester connected to data link connector No. 3 with ignition on to activate fuel pump or by connecting battery voltage to terminals on electric fuel pump.

REGULATED FUEL PRESSURE (4-CYLINDER) At Idle W/Vacuum psi Application (kg/cm2 ) (1) Camry, Camry Solara, Celica, Corolla, ECHO, Highlander & MR2 Prius (2) RAV4 Tacoma
(1) (1) (3)

At Idle W/O Vacuum psi (kg/cm2 )

(1) (1) (1) (3)

(1) Fuel pressure should be 44-50 psi (3.1-3.5 kg/cm2 ) with engine idling. Fuel pressure regulator is

not vacuum controlled, as fuel pressure regulator is mounted on electric fuel pump in the fuel tank. (2) Read service precautions before proceeding with service procedure. See SERVICE PRECAUTIONS . (3) Check vacuum hose routing for fuel pressure regulator to determine if fuel pressure regulator is vacuum controlled. If vacuum hose is connected to engine vacuum and not vented to the air cleaner assembly, fuel pressure regulator is vacuum controlled. If vacuum hose is vented to air cleaner assembly and not to engine vacuum, fuel pressure regulator is not vacuum controlled. On models with vacuum controlled fuel pressure regulator, fuel pressure should be 31-37 psi (2.2-2.6 kg/cm2 ) with engine idling and vacuum applied, and 38-44 (2.7-3.1 psi 2.7-3.1 kg/cm2 ) without vacuum with engine idling. On models without vacuum controlled fuel pressure regulator, fuel pressure should be 38-44 psi (2.7-3.1 kg/cm2 ) with engine idling.

2002 ENGINE PERFORMANCE Service & Adjustment Specifications

REGULATED FUEL PRESSURE (V6) Application Avalon, Camry, Camry Solara, Highlander & Sienna Tacoma, Tundra & 4Runner At Idle W/Vacuum psi (kg/cm2 )
(1) (2)

At Idle W/O Vacuum psi (kg/cm2 )

(1) (2)

(1) Fuel pressure should be 44-50 psi (3.1-3.5 kg/cm2 ) with engine idling. Fuel pressure regulator is

not vacuum controlled, as fuel pressure regulator is mounted on electric fuel pump in the fuel tank. (2) Check vacuum hose routing for fuel pressure regulator to determine if fuel pressure regulator is vacuum controlled. If vacuum hose is connected to engine vacuum and not vented to the air cleaner assembly, fuel pressure regulator is vacuum controlled. If vacuum hose is vented to air cleaner assembly and not to engine vacuum, fuel pressure regulator is not vacuum controlled. On models with vacuum controlled fuel pressure regulator, fuel pressure should be 33-38 psi (2.3-2.7 (kg/cm2 ) with engine idling and vacuum applied, and 38-44 psi (2.7-3.1 kg/cm2 ) without vacuum with engine idling. On models without vacuum controlled fuel pressure regulator, fuel pressure should be 38-44 psi (2.7-3.1 kg/cm2 ) with engine idling. REGULATED FUEL PRESSURE (V8) Application Land Cruiser, Sequoia & Tundra vacuum controlled. FUEL PUMP RESISTANCE Application All Models FUEL INJECTOR RESISTANCE FUEL INJECTOR RESISTANCE Application Avalon, Camry, Camry Solara, Celica, Corolla, ECHO, Highlander, Land Cruiser & MR2 At Idle W/Vacuum psi (kg/cm2 )
(1)

At Idle W/O Vacuum psi (kg/cm2 )

(1)

(1) Fuel pressure should be 38-44 (2.7-3.1 kg/cm2 ) with engine idling. Fuel pressure regulator is not

Ohms @ 68F (20C) .2-3.0

Ohms @ 68F (20C) 13.40-14.20 13.40-14.20 13.40-14.20 12.00-16.00 13.80 13.40-14.20 13.80

Prius (1) RAV4, Sequoia & Sienna Tacoma 2.4L 4-Cyl. & 2.7L 4-Cyl. 3.4L V6 Tundra 3.4L V6 & 4.7L V8 4Runner (1) Read service precautions before proceeding with service procedure. See SERVICE

2002 ENGINE PERFORMANCE Service & Adjustment Specifications

PRECAUTIONS . IDLE SPEED & MIXTURE IDLE SPEED SPECIFICATIONS (4-CYLINDER) (1) Application Camry A/T M/T Camry Solara A/T M/T Celica 1.8L (1ZZ-FE) A/T M/T 1.8L (2ZZ-GE) A/T M/T Corolla ECHO A/T M/T Highlander MR2

RPM 610-710 650-750 600-700 650-750

700-800 650-750 700-800 750-850 650-750 650-750 600-700 600-700 650-750 950-1050

Prius (2) RAV4 & Tacoma 650-750 (1) Check with engine at normal operating temperature, transaxle/transmission in Neutral (except Prius, in Park on Prius), parking brake applied, air cleaner and all air intake hoses installed, all vacuum hoses installed, electronic fuel injection system wiring connectors properly installed, ignition timing properly set, electric cooling fan off (if equipped), and A/C and all accessories off. (2) Read service precautions before proceeding with service procedure. See SERVICE PRECAUTIONS . Check with transit in inspection mode and transaxle in Park.

IDLE SPEED SPECIFICATIONS (V6) (1) Application RPM Avalon 600-700 Camry 550-650 Camry Solara, Highlander, Sienna, Tacoma, Tundra & 4Runner 650-750 (1) Check with engine at normal operating temperature, transaxle/transmission in Neutral, parking brake applied, air cleaner and all air intake hoses installed, all vacuum hoses installed, electronic fuel injection system wiring connectors properly installed, ignition timing properly set, and A/C and all accessories off.

2002 ENGINE PERFORMANCE Service & Adjustment Specifications

IDLE SPEED SPECIFICATIONS (V8)(1) Application RPM Land Cruiser, Sequoia & Tundra 650-750 (1) Check with engine at normal operating temperature, transmission in Neutral, parking brake applied, air cleaner and all air intake hoses installed, all vacuum hoses installed, electronic fuel injection system wiring connectors properly installed, ignition timing properly set, and A/C and all accessories off. DASHPOT SPECIFICATIONS DASHPOT SPECIFICATIONS (1) Application Tacoma 3.4L V6 M/T (1) Check with engine at normal operating temperature. THROTTLE OPENER THROTTLE OPENER SPECIFICATIONS (1) Application RPM Avalon 1100-1700 Camry Solara 3.0L V6 900-1950 Sienna 900-1950 Tacoma 2.4L 4-Cyl. & 2.7L 4-Cyl. 1200-1500 3.4L V6 900-1950 Tundra 3.4L V6 900-1950 (1) Check with engine at normal operating temperature and throttle opener vacuum hose disconnected and plugged. FUEL CUT SYSTEM FUEL CUT SPECIFICATIONS (1) Application Avalon Camry Camry Solara 2.4L 4-Cyl. A/T M/T 3.0L V6 Celica, Corolla & ECHO Highlander

RPM 1800-2200

Fuel Return RPM 1200

(2)

1500 1200 1200 1400

2002 ENGINE PERFORMANCE Service & Adjustment Specifications

(2)

Land Cruiser MR2 Prius (3) RAV4 & Sequoia Sienna Tacoma 2.4L 4-Cyl. & 2.7L 4-Cyl. A/T M/T 3.4L V6 A/T M/T Tundra 3.4L V6 A/T M/T 4.7L V8 4Runner (1) Check with engine at normal operating temperature and A/C off.
(2) Information is not available from manufacturer. (3) Read service precautions before proceeding with service procedure. See SERVICE

1000 1400 1400 1400 1200

1500 1400 1200 1000

1200 1000 1000 1500

PRECAUTIONS . THROTTLE POSITION SENSOR NOTE: Throttle position sensor is not adjustable. For testing procedures, see appropriate SYSTEM & COMPONENT TESTING article. WARNING: On Prius, read service precautions before proceeding with service procedure. See SERVICE PRECAUTIONS . THROTTLE POSITION SENSOR RESISTANCE SPECIFICATIONS (AVALON) (1) Throttle Position Terminals Ohms Fully Closed VTA & E2 200-6300 Fully Open VTA & E2 2000-10,200 ..... VC & E2 2500-5900 (1) Apply vacuum to throttle opener before checking throttle position sensor TP sensor. THROTTLE POSITION SENSOR RESISTANCE SPECIFICATIONS (CAMRY) Terminals Ohms (1) 1200-3200 VC & E2

2002 ENGINE PERFORMANCE Service & Adjustment Specifications

(1) Resistance at 68F (20C).

THROTTLE POSITION SENSOR RESISTANCE SPECIFICATIONS (CAMRY SOLARA) Application Throttle Position Terminals Ohms (1) 1200-3200 2.4L 4-Cyl. .... VC & E2 3.0L V6 (2) ..... Fully Closed ..... Fully Open ..... (1) Resistance at 68F (20C). VTA & E2 VTA & E2 VC & E2 200-6300 2000-10,200 2500-5900

(2) Apply vacuum to throttle opener before checking throttle position sensor.

THROTTLE POSITION SENSOR RESISTANCE SPECIFICATIONS (CELICA, COROLLA & ECHO) Throttle Position Terminals Ohms Fully Closed VTA & E2 200-5700 Fully Open VTA & E2 2000-10,200 ..... VC & E2 2500-5900 THROTTLE POSITION SENSOR RESISTANCE SPECIFICATIONS (HIGHLANDER) Throttle Position Terminals Ohms Fully Closed VTA & E2 200-5700 Fully Open VTA & E2 2000-10,200 ..... VC & E2 2500-5000 THROTTLE POSITION SENSOR RESISTANCE SPECIFICATIONS (LAND CRUISER) Terminals Ohms (1) 1250-2350 VC & E2
(1) Resistance at 68F (20C).

THROTTLE POSITION SENSOR RESISTANCE SPECIFICATIONS (MR2) Throttle Position Terminals Models With Standard Type Manual Transaxle (1) Fully Closed Fully Open ..... Models With Sequential Manual Transaxle Transaxle (1) .... VTA & E2 VTA & E2 VC & E2 VC & E2

Ohms 200-5700 2000-10,200 2500-5900

(2) 1200-3200

(1) There are 2 types of manual transaxles used. A standard type manual transaxle and a sequential

manual transaxle. Standard type manual transaxle is a common transaxle in which the driver operates the clutch and shifts the transaxle. Sequential manual transaxle is an electronic controlled manual transaxle in which clutch is operated and transaxle is shifted hydraulically by moving shift

2002 ENGINE PERFORMANCE Service & Adjustment Specifications

lever forward or backward. Sequential manual transaxle may be identified by shift lever pattern which consists of "R", "N", "S" and "+" in place of the conventional type shift lever pattern and no clutch pedal is used. (2) Resistance at 68F (20C). THROTTLE POSITION SENSOR RESISTANCE SPECIFICATIONS (PRIUS) (1) Terminals Ohms (2) 1200-3200 VC & E2
(1) Read service precautions before proceeding with service procedure. See SERVICE

PRECAUTIONS . (2) Resistance at 68F (20C). THROTTLE POSITION SENSOR RESISTANCE SPECIFICATIONS (RAV4) Throttle Position Terminals Fully Closed VTA & E2 Fully Open VTA & E2 ..... VC & E2

Ohms 200-5700 2000-10,200 2500-5900

THROTTLE POSITION SENSOR RESISTANCE SPECIFICATIONS (SEQUOIA) Terminals Ohms (1) 1250-2350 VC & E2
(1) Resistance at 68F (20C).

THROTTLE POSITION SENSOR RESISTANCE SPECIFICATIONS (SIENNA) (1) Throttle Position Terminals Ohms Fully Closed VTA & E2 200-6300 Fully Open VTA & E2 2000-10,200 ..... VC & E2 2500-5900 (1) Apply vacuum to throttle opener before checking throttle position sensor. THROTTLE POSITION SENSOR RESISTANCE SPECIFICATIONS (TACOMA) (1) Throttle Position Terminals Ohms Fully Closed VTA & E2 200-5700 Fully Open VTA & E2 2000-10,200 ..... VC & E2 2500-5900 (1) Apply vacuum to throttle opener before checking throttle position sensor. THROTTLE POSITION SENSOR RESISTANCE SPECIFICATIONS (TUNDRA) Application Throttle Position Terminals (1) Fully Closed VTA & E2 3.4L V6 ..... Fully Open VTA & E2

Ohms 200-5700 2000-10,200

2002 ENGINE PERFORMANCE Service & Adjustment Specifications

..... 4.7L V8
(2) Resistance at 68F (20C).

..... .....

VC & E2 VC & E2

2500-5900
(2) 1250-2350

(1) Apply vacuum to throttle opener before checking throttle position sensor.

THROTTLE POSITION SENSOR RESISTANCE SPECIFICATIONS (4RUNNER) Terminals Ohms (1) 1200-3200 VC & E2
(1) Resistance at 68F (20C).

2002 ENGINE PERFORMANCE Basic Diagnostic Procedures - 4-Cylinder

2002 ENGINE PERFORMANCE Basic Diagnostic Procedures - 4-Cylinder

SERVICE PRECAUTIONS
NOTE: Before performing basic diagnostic procedures, check for any related Technical Service Bulletins (TSBs).

PRIUS WARNING: When performing any inspection or service procedure on this vehicle, ensure following service precautions are followed to prevent personal injury or death due to the extremely high voltage. The following service precautions must be followed:

Ensure ignition is off and ignition key is removed from ignition before performing any inspection or service procedure in engine compartment, as engine may automatically start and shut off when ignition is on and READY light is illuminated. READY light is displayed just above the shift lever position indicator on instrument cluster at center of instrument panel. Read all service and warning labels in engine compartment before performing any procedures in engine compartment. All high-voltage wiring harness connectors contain Orange connectors. DO NOT touch any wiring harness that contains Orange connectors. High-voltage battery and other high-voltage components may be identified by HIGH VOLTAGE caution labels on them. DO NOT touch these components. If necessary to inspect or service high-voltage system, ensure ignition is off. Remove service plug and wait at least 5 minutes to ensure high voltage is fully discharged before touching any high-voltage wiring harness, connectors or components. Service plug is located on service plug assembly at driver's side front corner of trunk compartment, near high-voltage battery. See Fig. 1 . Ensure service plug is stored in a location in which no one may install service plug while technician is working on the vehicle. If necessary to touch any high-voltage wiring harness, connectors or components, ensure service plug is removed and battery voltage or less exists at electrical connector. Use Toyota insulated gloves when touching any high-voltage wiring harness, connectors or components. Ensure insulated gloves are dry and in good condition and that no holes exist in insulated gloves. Test by applying air pressure to insulated glove before touching any high-voltage wiring harness, connectors or components. DO NOT wear any metal objects while working on vehicle which may accidently drop and cause a short circuit. If any high-voltage wiring harness connector is disconnected, ensure terminal on wiring harness connector is wrapped with tape to prevent wiring harness connector from contacting any surface. If servicing high-voltage system, place sign on roof of vehicle to indicate to other technicians that high-voltage system is being serviced.

2002 ENGINE PERFORMANCE Basic Diagnostic Procedures - 4-Cylinder

Fig. 1: Locating Service Plug & Service Plug Assembly (Prius) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

PROGRAMMING
POWER SUN ROOF REINITIALIZATION PROCEDURE

2002 ENGINE PERFORMANCE Basic Diagnostic Procedures - 4-Cylinder

Camry

NOTE:

Following procedure should be performed if battery is disconnected and reconnected, or battery is discharged and recharged to provide proper automatic operation and jam protection operation of power sun roof.

1. Ensure ignition is on. Depress and hold TILT UP side of power sun roof switch until power sun roof tilts all the way upward and then tilts downward a little. Power sun roof switch is located on headliner, just in front of power sun roof. 2. Check proper operation of open/closing and tilt up/down function for power sun roof using power sun roof switch. Power sun roof should operate anytime ignition is on, or for 43 seconds after ignition is off provided both front doors are closed. Power sun roof will stop operating if any front door is opened. Depressing SLIDE OPEN side of power sun roof switch for one second should open power sun roof. Depressing TILT UP side of power sun roof switch for one second should close power sun roof. To tilt power sun roof upward, depress and hold TILT UP side of power sun roof switch for one second. To tilt power sun roof downward, depress and hold SLIDE OPEN side of power sun roof switch for one second.
Celica

NOTE:

Following procedure should be performed if battery is disconnected and reconnected, or battery is discharged and recharged to provide proper automatic operation and jam protection operation of power sun roof.

Close power sun roof using power sun roof switch and continue to depress power sun roof switch briefly after power sun roof is fully closed. Power sun roof switch is located on headliner, just in front of power sun roof.

INTRODUCTION
NOTE: On Camry, Camry Solara, Highlander, MR2, Prius and RAV4, an engine immobilizer system may be used. Engine immobilizer system is a theft deterrent system which disables the engine from starting by not allowing ignition system operation and fuel injector operation unless proper ignition key is used. Models equipped with engine immobilizer system may be identified by looking at the ignition key. On models equipped with engine immobilizer system the top of the ignition key is thicker than a standard ignition key, as a transponder chip is incorporated into the top of the ignition key. For additional information on system operation and testing, see appropriate ENGINE IMMOBILIZER SYSTEMS article in ACCESSORIES & EQUIPMENT.

Before proceeding with basic diagnostic service procedures, ensure testing procedure is followed, as some systems which may result in a no-start condition may cause a Diagnostic Trouble Code (DTC) to be stored in the Engine Control Module (ECM). See TESTING PROCEDURE under SELF-DIAGNOSTIC SYSTEM in appropriate SELF-DIAGNOSTICS article. If no-start condition still exists after checking and repairing all DTCs, perform a careful and complete visual inspection. Many problems result from mechanical breakdowns, poor electrical connections or damaged/misrouted vacuum hoses. Before condemning the computerized system, perform each test listed in

2002 ENGINE PERFORMANCE Basic Diagnostic Procedures - 4-Cylinder

this article. NOTE: Perform all voltage tests with a Digital Volt-Ohmmeter (DVOM) with a minimum 10-megohm input impedance, unless stated otherwise in test procedure.

PRELIMINARY INSPECTION & ADJUSTMENTS

VISUAL INSPECTION Visually inspect all electrical wiring, looking for chafed, stretched, cut or pinched wiring. Ensure electrical connectors fit tightly and are not corroded. Ensure vacuum hoses are properly routed and are not pinched or cut. See VACUUM DIAGRAMS article to verify routing and connections (if necessary). Inspect air induction system for possible vacuum leaks. MECHANICAL INSPECTION
Compression (Camry & Camry Solara)

Warm engine to normal operating temperature before checking the compression. Ensure battery is fully charged. Disconnect electrical connectors at fuel injectors and ignition coils. Remove ignition coils and spark plugs. Using compression gauge, check compression with throttle fully open. Read compression in a short a time as possible. Ensure compression is within specification. See COMPRESSION SPECIFICATIONS table. Install and tighten spark plugs to 14 ft. lbs. (19 N.m) and ignition coil retaining bolts to 80 INCH lbs. (9.0 N.m).
Compression (Celica, Corolla & ECHO)

Warm engine to normal operating temperature before checking the compression. Ensure battery is fully charged. Disconnect electrical connectors at ignition coils. Remove ignition coils and spark plugs. Using compression gauge, check compression with throttle fully open. Read compression in a short a time as possible. Ensure compression is within specification. See COMPRESSION SPECIFICATIONS table. On Celica and ECHO, install and tighten spark plugs to 13 ft. lbs. (18 N.m) and ignition coil retaining bolts to 80 INCH lbs. (9.0 N.m). On Corolla, install and tighten spark plugs to 13 ft. lbs. (18 N.m) and ignition coil retaining bolts to 62 INCH lbs. (7.0 N.m).
Compression (Highlander)

Warm engine to normal operating temperature before checking the compression. Ensure battery is fully charged. Disconnect electrical connectors at fuel injectors and ignition coils. Remove ignition coils and spark plugs. Using compression gauge, check compression with throttle fully open. Read compression in a short a time as possible. Ensure compression is within specification. See COMPRESSION SPECIFICATIONS table. Install and tighten spark plugs to 14 ft. lbs. (19 N.m) and ignition coil retaining bolts to 80 INCH lbs. (9.0 N.m).
Compression (MR2)

Warm engine to normal operating temperature before checking the compression. Ensure battery is fully charged. Disconnect electrical connectors at ignition coils. Remove ignition coils and spark plugs. Using compression gauge, check compression with throttle fully open. Read compression in a short a time as possible. Ensure compression is within specification. See COMPRESSION SPECIFICATIONS table.

2002 ENGINE PERFORMANCE Basic Diagnostic Procedures - 4-Cylinder

Install and tighten spark plugs to 19 ft. lbs. (26 N.m) and ignition coil retaining bolts to 80 INCH lbs. (9.0 N.m).
Compression (Prius)

WARNING: Read service precautions before proceeding with service procedure. See SERVICE PRECAUTIONS . 1. Manufacturer states procedure using Toyota hand-held tester. Warm engine to normal operating temperature. Shut engine off. Remove air cleaner assembly. Disconnect electrical connectors at ignition coils. Remove ignition coils and spark plugs. 2. Connect Toyota hand-held tester to data link connector No. 3 at driver's side of instrument panel. See Fig. 9 . Select CRANKING MODE on Toyota hand-held tester using hand-held tester instructions. 3. Connect compression gauge. Crank the engine and note the compression. While in the CRANKING MODE, cranking speed is automatically set at 250 RPM and throttle is automatically opened to fully open position. Read compression in a short a time as possible. Ensure compression is within specification. See COMPRESSION SPECIFICATIONS table. Remove hand-held tester. Install and tighten spark plugs to 13 ft. lbs. (18 N.m) and ignition coil retaining bolts to 80 INCH lbs. (9.0 N.m).
Compression (RAV4)

Warm engine to normal operating temperature before checking the compression. Ensure battery is fully charged. Disconnect electrical connectors at ignition coils. Remove ignition coils and spark plugs. Using compression gauge, check compression with throttle fully open. Read compression in a short a time as possible. Ensure compression is within specification. See COMPRESSION SPECIFICATIONS table. Install and tighten spark plugs to 14 ft. lbs. (19 N.m) and ignition coil retaining bolts to 80 INCH lbs. (9.0 N.m).
Compression (Tacoma)

1. Warm engine to normal operating temperature before checking the compression. Remove intake air connector for access to spark plugs. Intake air connector fits between air cleaner hose and throttle body. 2. Disconnect electrical connectors at ignition coils. Remove ignition coils and spark plugs. Using compression gauge, check compression with throttle fully open. Read compression in a short a time as possible. Ensure compression is within specification. See COMPRESSION SPECIFICATIONS table. Install and tighten spark plugs to 15 ft. lbs. (20 N.m) and ignition coil retaining bolts to 66 INCH lbs. (7.5 N.m). COMPRESSION SPECIFICATIONS Application Normal Compression Pressure Camry & Camry Solara Celica 1.8L (1ZZ-FE) 1.8L (2ZZ-GE) Corolla

Specification 198 psi (13.9 kg/cm2 ) 218 psi (15.3 kg/cm2 ) 203 psi (14.3 kg/cm2 ) 218 psi (15.3 kg/cm2 )

2002 ENGINE PERFORMANCE Basic Diagnostic Procedures - 4-Cylinder

ECHO Highlander MR2 Prius RAV4 Tacoma Minimum Compression Pressure Camry & Camry Solara Celica 1.8L (1ZZ-FE) & 1.8L (2ZZ-GE) Corolla ECHO Highlander MR2 Prius RAV4 Tacoma Maximum Variation Between Cylinders Camry & Camry Solara Celica 1.8L (1ZZ-FE) 1.8L (2ZZ-GE) Corolla, ECHO, Highlander, MR2, Prius, RAV4 & Tacoma

213 psi (15.0 kg/cm2 ) 198 psi (13.9 kg/cm2 ) 184 psi (13.0 kg/cm2 ) 106 psi (7.4 kg/cm2 ) 184 psi (13.0 kg/cm2 ) 178 psi (12.5 kg/cm2 ) 142 psi (10.0 kg/cm2 ) 145 psi (10.2 kg/cm2 ) 145 psi (10.2 kg/cm2 ) 156 psi (11.0 kg/cm2 ) 142 psi (10.0 kg/cm2 ) 145 psi (10.2 kg/cm2 ) 77 psi (5.4 kg/cm2 ) 145 psi (10.2 kg/cm2 ) 128 psi (9.0 kg/cm2 ) 14 psi (1.0 kg/cm2 ) 14 psi (1.0 kg/cm2 ) 16 psi (1.1 kg/cm2 ) 14 psi (1.0 kg/cm2 )

FUEL SYSTEMS
NOTE: Basic diagnosis of fuel system should begin by checking fuel pump operation and fuel pressure. WARNING: ALWAYS release fuel pressure before disconnecting any fuel injectionrelated component. DO NOT allow fuel to contact engine or electrical components. FUEL PUMP OPERATION NOTE: Electric fuel pump operation may be checked by using Toyota hand-held tester or by applying battery voltage to the fuel pump. Fuel pump is located in the fuel tank.

Checking Fuel Pump Operation Using Toyota Hand-Held Tester (Camry)

1. Connect hand-held tester to data link connector No. 3 at driver's side of instrument panel. See Fig. 2 .

2002 ENGINE PERFORMANCE Basic Diagnostic Procedures - 4-Cylinder

Turn ignition on. DO NOT start engine. 2. Turn hand-held tester on. Select ACTIVE TEST MODE on hand-held tester. Using hand-held tester manufacturer's instructions, operate fuel pump. Listen for fuel pump operating sound and feel for fuel pressure in fuel inlet line at end of fuel rail. Turn ignition off. Remove hand-held tester. If fuel pump operates, check fuel pressure. See FUEL PRESSURE . 3. If fuel pump does not operate, EFI main relay or circuit opening relay may be defective. For relay application and explanation of relay operation, see FUEL PUMP CONTROL CIRCUIT . For testing of EFI main relay or circuit opening relay, see appropriate relay under MODULES, MOTORS, RELAYS & SOLENOIDS in SYSTEM & COMPONENT TESTING - 4-CYLINDER article. 4. If relays are okay, check for defective fuel pump. See CHECKING FUEL PUMP OPERATION BY APPLYING BATTERY VOLTAGE TO FUEL PUMP (CAMRY) procedure. If fuel pump operates properly, Engine Control Module (ECM) may be defective. NOTE: For additional testing information for fuel pump control circuit, see FUEL PUMP CONTROL CIRCUIT under COMPUTERIZED ENGINE CONTROLS in SYSTEM & COMPONENT TESTING - 4-CYLINDER article.

Checking Fuel Pump Operation Using Toyota Hand-Held Tester (Camry Solara & Tacoma)

1. Connect hand-held tester to data link connector No. 3 at driver's side of instrument panel. See Fig. 3 and Fig. 11 . Turn ignition on. DO NOT start engine. 2. Turn hand-held tester on. Select ACTIVE TEST MODE on hand-held tester. Using hand-held tester manufacturer's instructions, operate fuel pump. Listen for fuel pump operating sound and feel for fuel pressure in fuel inlet line at fuel filter. Turn ignition off. Remove hand-held tester. If fuel pump operates, check fuel pressure. See FUEL PRESSURE . 3. If fuel pump does not operate, EFI main relay or circuit opening relay may be defective. For relay application and explanation of relay operation, see FUEL PUMP CONTROL CIRCUIT . For testing of EFI main relay or circuit opening relay, see appropriate relay under MODULES, MOTORS, RELAYS & SOLENOIDS in SYSTEM & COMPONENT TESTING - 4-CYLINDER article. 4. If relays are okay, check for defective fuses, fusible links or wiring. See WIRING DIAGRAMS article. If fuses, fusible links and wiring are okay, check for defective fuel pump. See appropriate CHECKING FUEL PUMP OPERATION BY APPLYING BATTERY VOLTAGE TO FUEL PUMP procedure. If fuel pump operates properly, Engine Control Module (ECM) may be defective. NOTE: For additional testing information for fuel pump control circuit, see FUEL PUMP CONTROL CIRCUIT under COMPUTERIZED ENGINE CONTROLS in SYSTEM & COMPONENT TESTING - 4-CYLINDER article.

Checking Fuel Pump Operation Using Toyota Hand-Held Tester (Celica, Corolla, ECHO, Highlander, MR2, Prius & RAV4)

WARNING: On Prius, read service precautions before proceeding with service procedure. See SERVICE PRECAUTIONS . 1. Connect hand-held tester to data link connector No. 3 at driver's side of instrument panel. See Fig. 4 Fig. 10 . Turn ignition on. DO NOT start engine. 2. Turn hand-held tester on. Select ACTIVE TEST MODE on hand-held tester. Using hand-held tester manufacturer's instructions, operate fuel pump. Listen for fuel pump operating sound and feel for fuel

2002 ENGINE PERFORMANCE Basic Diagnostic Procedures - 4-Cylinder

pressure in fuel inlet pipe at end of fuel rail. Turn ignition off. Remove hand-held tester. If fuel pump operates, check fuel pressure. See FUEL PRESSURE . 3. If fuel pump does not operate, EFI main relay or circuit opening relay may be defective. For relay application and explanation of relay operation, see FUEL PUMP CONTROL CIRCUIT . For testing of EFI main relay or circuit opening relay, see appropriate relay under MODULES, MOTORS, RELAYS & SOLENOIDS in SYSTEM & COMPONENT TESTING - 4-CYLINDER article. 4. If relays are okay, check for defective fuses, fusible links or wiring. See WIRING DIAGRAMS article. If fuses, fusible links and wiring are okay, check for defective fuel pump. See appropriate CHECKING FUEL PUMP OPERATION BY APPLYING BATTERY VOLTAGE TO FUEL PUMP procedure. If fuel pump operates properly, Engine Control Module (ECM) may be defective. NOTE: For additional testing information for fuel pump control circuit, see FUEL PUMP CONTROL CIRCUIT under COMPUTERIZED ENGINE CONTROLS in SYSTEM & COMPONENT TESTING - 4-CYLINDER article.

Fig. 2: Locating Data Link Connector No. 3 (Camry) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 ENGINE PERFORMANCE Basic Diagnostic Procedures - 4-Cylinder

Fig. 5: Locating Data Link Connector No. 3 (Corolla) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 ENGINE PERFORMANCE Basic Diagnostic Procedures - 4-Cylinder

Fig. 11: Locating Data Link Connector No. 3 (Tacoma) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Checking Fuel Pump Operation By Applying Battery Voltage To Fuel Pump (Camry)

NOTE:

On Camry, manufacturer lists procedure of applying battery voltage to fuel pump by removing circuit opening relay and checking fuel pump operation as well as wiring circuit to fuel pump. Also, manufacturer lists procedure for checking fuel pump operation by removing fuel pump from fuel tank and applying battery voltage directly to fuel pump. For testing of fuel pump with fuel pump removed from fuel tank, see appropriate FUEL PUMP RESISTANCE & OPERATION procedure under FUEL DELIVERY under FUEL SYSTEMS in SYSTEM & COMPONENT TESTING - 4-CYLINDER article.

1. Ensure ignition is off. Remove circuit opening relay from fuse/relay box. See Fig. 12 . Fuse/relay box is located at driver's side front corner of engine compartment. 2. Install jumper wire between FP and +B terminals in fuse/relay box for circuit opening relay. Turn ignition on and listen for fuel pump operating sound. Turn ignition off. Remove jumper wire. Reinstall circuit opening relay. 3. If fuel pump operates, EFI main relay, wiring circuit for fuel pump and fuel pump are okay. If fuel pump does not operate with jumper wire installed, it may be necessary to check for defective fuses, fusible links, wiring or EFI main relay. See WIRING DIAGRAMS article. If necessary to check fuel pump operation, see appropriate FUEL PUMP RESISTANCE & OPERATION procedure under FUEL DELIVERY under FUEL SYSTEMS in SYSTEM & COMPONENT TESTING - 4CYLINDER article. 4. If fuel pump operates with jumper wire installed but does not operate with circuit opening relay

2002 ENGINE PERFORMANCE Basic Diagnostic Procedures - 4-Cylinder

installed, circuit opening relay may be defective. For relay application and explanation of relay operation, see FUEL PUMP CONTROL CIRCUIT . For testing of EFI main relay or circuit opening relay, see appropriate relay under MODULES, MOTORS, RELAYS & SOLENOIDS in SYSTEM & COMPONENT TESTING - 4-CYLINDER article. Engine Control Module (ECM) may be defective if fuel pump still fails to operate. NOTE: For additional testing information for fuel pump control circuit, see FUEL PUMP CONTROL CIRCUIT under COMPUTERIZED ENGINE CONTROLS in SYSTEM & COMPONENT TESTING - 4-CYLINDER article.

Fig. 12: Locating Circuit Opening Relay & Identifying FP & +B Cavities For Circuit Opening Relay (Camry) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Checking Fuel Pump Operation By Applying Battery Voltage To Fuel Pump (Camry Solara, Celica, Corolla, ECHO, Highlander, MR2, Prius, RAV4 & Tacoma)

2002 ENGINE PERFORMANCE Basic Diagnostic Procedures - 4-Cylinder

WARNING: On Prius, read service precautions before proceeding with service procedure. See SERVICE PRECAUTIONS . 1. On Camry Solara, Celica, Corolla, ECHO and Prius, remove rear seat cushion, cover plate on floor panel and any remaining necessary covers for access to electrical connector for fuel pump. 2. On Highlander, remove driver's side and passenger's side rear seats and cover plate on floor panel for access to electrical connector for fuel pump. 3. On MR2, remove luggage compartment lids, quarter trim covers, lower trim covers and luggage compartment boxes behind driver's and passenger's seats, and cover plate on floor panel for access to electrical connector for fuel pump. See Fig. 22 . For additional information on removal of luggage compartment components, see FUEL PUMP under FUEL SYSTEMS in REMOVAL, OVERHAUL & INSTALLATION - 4-CYLINDER article. 4. On RAV4, remove driver's side rear seat and cover plate on floor panel for access to electrical connector for fuel pump. 5. On Tacoma, it may be necessary to lower fuel tank for access to electrical connector for fuel pump. 6. On all models, disconnect electrical connector for fuel pump. This is electrical connector for fuel pump and fuel gauge sending unit and is located on top of fuel tank, near fuel pump. CAUTION: When applying battery voltage to fuel pump, DO NOT apply battery voltage for more than 10 seconds or fuel pump may be damaged. Keep battery as far away from fuel pump as possible. Always connect jumper wires to fuel pump and then to the battery when applying battery voltage to fuel pump. 7. Connect battery voltage to specified terminals on fuel pump to operate fuel pump. See Fig. 13 -Fig. 21 . DO NOT apply battery voltage to fuel pump for more than 10 seconds. 8. Listen for fuel pump operating sound. Disconnect battery voltage from fuel pump. If fuel pump operates, check fuel pressure after reinstalling components. See FUEL PRESSURE . 9. If fuel pump fails to operate, replace fuel pump and/or lead wire to fuel pump (if equipped). See FUEL PUMP under FUEL SYSTEMS in SYSTEM & COMPONENT TESTING - 4-CYLINDER article. On Prius, it may be necessary to replace fuel pump and fuel tank as an assembly. Consult parts department for parts availability. On all models, if fuel pump will not operate while trying to start engine, see appropriate CHECKING FUEL PUMP OPERATION USING TOYOTA HAND-HELD TESTER procedure under FUEL PUMP OPERATION for additional testing information. NOTE: For additional testing information for fuel pump control circuit, see FUEL PUMP CONTROL CIRCUIT under COMPUTERIZED ENGINE CONTROLS in SYSTEM & COMPONENT TESTING - 4-CYLINDER article.

2002 ENGINE PERFORMANCE Basic Diagnostic Procedures - 4-Cylinder

will not start. Turn ignition off. Disconnect negative battery cable. Remove fuel tank cap to release any pressure from fuel tank. 3. Place suitable container under fuel line connection. Cover fuel line connection with shop towel. Slowly loosen or disconnect fuel line connection, allowing fuel pressure to be released. Once fuel pressure is released, fuel system components may be serviced. 4. Reinstall circuit opening relay and negative battery cable. Start engine and check operation of Malfunction Indicator Light (MIL) on instrument panel with engine running. MIL is displayed as engine icon on instrument panel. It may be possible that Diagnostic Trouble Code (DTC) P0171 may have been stored in Engine Control Module (ECM) and MIL may be illuminated with engine running due to the lean condition caused by operating engine with circuit opening relay removed. If MIL is illuminated, DTCs must be cleared from ECM. See CLEARING DIAGNOSTIC TROUBLE CODES under SELF-DIAGNOSTIC SYSTEM in appropriate SELF-DIAGNOSTICS article. NOTE: It may be possible that power sun roof may not operate properly after battery was disconnected. If power sun roof does not operate properly, perform appropriate power sun roof reinitialization procedure. See appropriate POWER SUN ROOF REINITIALIZATION PROCEDURE under PROGRAMMING.

Camry Solara, Celica, Corolla, ECHO, Highlander, MR2, Prius, RAV4 & Tacoma

WARNING: On Prius, read service precautions before proceeding with service procedure. See SERVICE PRECAUTIONS . 1. On all models, disconnect electrical connector for fuel pump. See FUEL PUMP ELECTRICAL CONNECTOR LOCATION table. This is electrical connector for fuel pump and fuel gauge sending unit. Electric fuel pump is located in the fuel tank. FUEL PUMP ELECTRICAL CONNECTOR LOCATION Application Connector Location Camry Solara, Celica, Corolla, Under Cover Plate, Below ECHO & Prius Rear Seat Cushion Highlander Under Cover Plate, Below Driver's Side & Passenger's Side Rear Seats MR2 Under Cover Plate, Below Luggage Compartment Boxes Behind The Seats RAV4 Under Cover Plate, Below Driver's Side Rear Seat Tacoma On Top Of Fuel Tank, At Fuel Pump 2. Start engine and allow engine to idle until engine stalls. Turn ignition off. Disconnect negative battery cable. 3. Place suitable container under fuel line connection. Cover fuel line connection with shop towel. Slowly loosen or disconnect fuel line connection, allowing fuel pressure to be released. Once fuel pressure is released, fuel system components may be serviced. Reinstall electrical connector for fuel

2002 ENGINE PERFORMANCE Basic Diagnostic Procedures - 4-Cylinder

pump and negative battery cable. NOTE: On Celica, it may be possible that power sun roof may not operate properly after battery was disconnected. If power sun roof does not operate properly, perform appropriate power sun roof reinitialization procedure. See appropriate POWER SUN ROOF REINITIALIZATION PROCEDURE under PROGRAMMING.

FUEL PRESSURE
Camry

1. Ensure battery is fully charged. Release fuel pressure. See FUEL SYSTEM PRESSURE RELEASE . Disconnect negative battery cable. 2. Purchase fuel pipe (part No. 23901-28130) from parts department. Remove fuel pipe connector from end of NEW fuel pipe. See Fig. 23 . 3. Remove fuel pipe clamp from end of fuel pipe at fuel pipe fitting. Perform STEP 1 in illustration. See Fig. 24 . Ensure area around fuel pipe and disconnect fitting is clean. CAUTION: Use care when disconnecting fuel pipe, as some residual fuel pressure may still exist in the fuel system. 4. Depress both tabs and pull fuel pipe with disconnect fitting from fuel pipe fitting. Perform STEP 2 in illustration. See Fig. 24 . Install Adapter (SST 09268-41250) and hose with fuel pressure gauge from Fuel Pressure Gauge Set (SST 09268-45014) with fuel pipe connector between fuel pipe and fuel pipe fitting. See Fig. 25 . Ensure hose, fuel pipe and fuel pipe connector are properly connected. Install fuel pipe clamp. 5. Install negative battery cable. Connect Toyota hand-held tester to data link connector No. 3 at driver's side of instrument panel. See Fig. 2 . Turn ignition on. DO NOT start engine. 6. Turn hand-held tester on. Select ACTIVE TEST MODE on hand-held tester. Using hand-held tester manufacturer's instructions, operate fuel pump and note fuel pressure. If hand-held tester is not available, fuel pump may also be activated by removing circuit opening relay and connecting battery voltage to wiring circuit for fuel pump. See CHECKING FUEL PUMP OPERATION BY APPLYING BATTERY VOLTAGE TO FUEL PUMP (CAMRY) under FUEL PUMP OPERATION. Fuel pressure should be 44-50 psi (3.1-3.5 kg/cm2 ). 7. If fuel pressure is within specification, go to next step. If fuel pressure exceeds specification, replace fuel pressure regulator mounted on fuel pump in the fuel tank. See FUEL PRESSURE REGULATOR under FUEL SYSTEMS in REMOVAL, OVERHAUL & INSTALLATION - 4-CYLINDER article. If fuel pressure is less than specified, check for leaking fuel hoses or connections, restricted fuel filter, defective fuel pump or defective fuel pressure regulator. 8. Turn ignition off. Remove hand-held tester. Start engine and allow engine to idle. Note fuel pressure with engine idling. Fuel pressure should be 44-50 psi (3.1-3.5 kg/cm2 ). 9. Shut engine off and note fuel pressure. Fuel pressure should remain at least 21 psi (1.5 kg/cm2 ) for a minimum of 5 minutes. If fuel pressure is within specification and holds as specified, go to next step. If fuel pressure is not within specification or does not hold as specified, check for defective fuel pump, fuel injector or fuel pressure regulator. 10. Release fuel pressure. Disconnect negative battery cable. Remove adapter, hose, fuel pressure gauge

2002 ENGINE PERFORMANCE Basic Diagnostic Procedures - 4-Cylinder

and fuel pipe connector. 11. Install fuel pipe on fuel pipe fitting. Pull on fuel pipe to ensure fuel pipe is properly locked on fuel pipe fitting. Reinstall fuel pipe clamp. Install negative battery cable. Check for fuel leaks by activating the fuel pump by using hand-held tester or by removing circuit opening relay and connecting battery voltage to wiring circuit for fuel pump. NOTE: It may be possible that power sun roof may not operate properly after battery was disconnected. If power sun roof does not operate properly, perform appropriate power sun roof reinitialization procedure. See appropriate POWER SUN ROOF REINITIALIZATION PROCEDURE under PROGRAMMING.

Fig. 23: Identifying Fuel Pipe Connector (Camry, ECHO, Highlander, Prius & RAV4) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 ENGINE PERFORMANCE Basic Diagnostic Procedures - 4-Cylinder

2. Purchase fuel pipe (part No. 23901-22070) from parts department. This is the fuel pipe that attaches to top of fuel filter. Remove fuel pipe connector from end of NEW fuel pipe. See Fig. 26 . 3. Remove fuel pipe clamp from fuel pipe at fuel filter. Perform STEP 1 in illustration. See Fig. 27 . Ensure area around fuel pipe and fuel filter is clean. CAUTION: Use care when disconnecting fuel pipe from fuel filter, as some residual fuel pressure may still exist in the fuel system. 4. Depress both sides of retainer and pull fuel pipe with disconnect fitting from fuel filter. Perform STEP 2 in illustration. See Fig. 27 . 5. Install Adapter (SST 09268-41250), hose and fuel pressure gauge from Fuel Pressure Gauge Set (SST 09268-45014) with fuel pipe connector between fuel pipe and fuel filter. See Fig. 28 . Ensure hose, fuel pipe and fuel pipe connector are properly connected. 6. Reinstall negative battery cable. Connect Toyota hand-held tester to data link connector No. 3 at driver's side of instrument panel. See Fig. 3 . Turn ignition on. DO NOT start engine. 7. Turn hand-held tester on. Select ACTIVE TEST MODE on hand-held tester. Using hand-held tester manufacturer's instructions, operate fuel pump and note fuel pressure. If hand-held tester is not available, fuel pump may also be activated by connecting battery voltage to specified terminals on fuel pump. See Fig. 13 . Fuel pressure should be 44-50 psi (3.1-3.5 kg/cm2 ). 8. If fuel pressure is within specification, go to next step. If fuel pressure exceeds specification, replace fuel pressure regulator mounted on fuel pump in the fuel tank. See FUEL PRESSURE REGULATOR under FUEL SYSTEMS in REMOVAL, OVERHAUL & INSTALLATION - 4-CYLINDER article. If fuel pressure is less than specified, check for leaking fuel hoses or connections, restricted fuel filter, defective fuel pump or defective fuel pressure regulator. 9. Turn ignition off. Remove hand-held tester. Start engine and allow engine to idle. Note fuel pressure with engine idling. Fuel pressure should be 44-50 psi (3.1-3.5 kg/cm2 ). 10. Shut engine off and note fuel pressure. Fuel pressure should remain at least 21 psi (1.5 kg/cm2 ) for a minimum of 5 minutes. If fuel pressure is within specification and holds as specified, go to next step. If fuel pressure is not within specification or does not hold as specified, check for defective fuel pump, fuel injector or fuel pressure regulator. 11. Release fuel pressure. Disconnect negative battery cable. Remove adapter, hose, fuel pressure gauge and fuel pipe connector. CAUTION: DO NOT reuse old retainer when installing fuel pipe on fuel filter. Always use a NEW retainer. 12. Apply light coat of engine oil on tip of fuel pipe on fuel filter to allow for ease of disconnect fitting and fuel pipe installation. Using NEW retainer, install fuel pipe on fuel filter until "click" sound is heard. DO NOT reuse old retainer. Pull on fuel pipe to ensure fuel pipe is properly locked on fuel filter. 13. Reinstall fuel pipe clamp. Install negative battery cable. Check for fuel leaks by activating the fuel pump by using hand-held tester or connecting battery voltage to fuel pump.

2002 ENGINE PERFORMANCE Basic Diagnostic Procedures - 4-Cylinder

Fig. 26: Identifying Fuel Pipe Connector (Camry Solara, Celica, Corolla & MR2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 ENGINE PERFORMANCE Basic Diagnostic Procedures - 4-Cylinder

Remove fuel pipe connector from end of NEW fuel pipe. See Fig. 23 and Fig. 26 . FUEL PIPE IDENTIFICATION Application Fuel Pipe Part No. Celica 1.8L 23901-22100 1ZZ-FE 1.8L 23271-88600 2ZZ-GE Corolla 23901-22010 ECHO 23901-21020 Or 23901-22010 MR2 23901-22070 3. Remove fuel pipe clamp from end of fuel pipe at end of fuel rail. Perform STEP 1 in illustration. See Fig. 29 -Fig. 32 . Ensure area around fuel pipe and disconnect fitting is clean. CAUTION: Use care when disconnecting fuel pipe, as some residual fuel pressure may still exist in the fuel system. 4. Depress both sides of retainer and pull fuel pipe with disconnect fitting from fuel pipe fitting. Perform STEP 2 in illustration. See Fig. 29 -Fig. 32 . 5. Install Adapter (SST 09268-41250) and hose with fuel pressure gauge from Fuel Pressure Gauge Set (SST 09268-45014) with fuel pipe connector between fuel pipe and fuel pipe fitting. See Fig. 33 . Ensure hose, fuel pipe and fuel pipe connector are properly connected. 6. Install negative battery cable. Connect Toyota hand-held tester to data link connector No. 3 at driver's side of instrument panel. See Fig. 4 , Fig. 5 , Fig. 6 and Fig. 8 . Turn ignition on. DO NOT start engine. 7. Turn hand-held tester on. Select ACTIVE TEST MODE on hand-held tester. Using hand-held tester manufacturer's instructions, operate fuel pump and note fuel pressure. If hand-held tester is not available, fuel pump may also be activated by connecting battery voltage to specified terminals on fuel pump. See Fig. 14 , Fig. 15 , Fig. 16 and Fig. 18 . Fuel pressure should be 44-50 psi (3.1-3.5 kg/cm2 ). 8. If fuel pressure is within specification, go to next step. If fuel pressure exceeds specification, replace fuel pressure regulator mounted on fuel pump in the fuel tank. See FUEL PRESSURE REGULATOR under FUEL SYSTEMS in REMOVAL, OVERHAUL & INSTALLATION - 4-CYLINDER article. If fuel pressure is less than specified, check for leaking fuel hoses or connections, restricted fuel filter, defective fuel pump or defective fuel pressure regulator. 9. Turn ignition off. Remove hand-held tester. Start engine and allow engine to idle. Note fuel pressure with engine idling. Fuel pressure should be 44-50 psi (3.1-3.5 kg/cm2 ). 10. Shut engine off and note fuel pressure. Fuel pressure should remain at least 21 psi (1.5 kg/cm2 ) for a minimum of 5 minutes. If fuel pressure is within specification and holds as specified, go to next step. If fuel pressure is not within specification or does not hold as specified, check for defective fuel pump, fuel injector or fuel pressure regulator. 11. Release fuel pressure. Disconnect negative battery cable. Remove adapter, hose, fuel pressure gauge and fuel pipe connector.

2002 ENGINE PERFORMANCE Basic Diagnostic Procedures - 4-Cylinder

CAUTION: DO NOT reuse old retainer when installing fuel pipe on fuel pipe fitting. Always use a NEW retainer. 12. Apply light coat of engine oil on tip of fuel pipe fitting to allow for ease of disconnect fitting and fuel pipe installation. Using NEW retainer, install fuel pipe on fuel pipe fitting until "click" sound is heard. DO NOT reuse old retainer. Pull on fuel pipe to ensure fuel pipe is properly locked on fuel pipe fitting. 13. Reinstall fuel pipe clamp. Install negative battery cable. Check for fuel leaks by activating the fuel pump by using hand-held tester or connecting battery voltage to fuel pump. NOTE: On Celica, it may be possible that power sun roof may not operate properly after battery was disconnected. If power sun roof does not operate properly, perform power sun roof reinitialization procedure. See appropriate POWER SUN ROOF REINITIALIZATION PROCEDURE under PROGRAMMING.

2002 ENGINE PERFORMANCE Basic Diagnostic Procedures - 4-Cylinder

Fig. 30: Locating Fuel Pipe Clamp & Disconnecting Fuel Pipe From Fuel Pipe Fitting (Corolla) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 ENGINE PERFORMANCE Basic Diagnostic Procedures - 4-Cylinder

Fig. 33: Installing Fuel Pressure Gauge (Celica, Corolla, ECHO, MR2, Prius & RAV4) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Highlander & RAV4

1. Ensure battery is fully charged. Release fuel pressure. See FUEL SYSTEM PRESSURE RELEASE . Disconnect negative battery cable. 2. Purchase fuel pipe (part No. 23901-28070 for Highlander or 23901-22110 for RAV4) from parts department. Remove fuel pipe connector from end of NEW fuel pipe. See Fig. 23 . 3. Remove fuel pipe clamp from end of fuel pipe at fuel pipe fitting. See Fig. 34 and Fig. 35 . Ensure area around fuel pipe and disconnect fitting is clean.

2002 ENGINE PERFORMANCE Basic Diagnostic Procedures - 4-Cylinder

CAUTION: Use care when disconnecting fuel pipe, as some residual fuel pressure may still exist in the fuel system. 4. Depress both tabs and pull fuel pipe with disconnect fitting from fuel pipe fitting. See Fig. 34 and Fig. 35 . Install Adapter (SST 09268-41250) and hose with fuel pressure gauge from Fuel Pressure Gauge Set (SST 09268-45014) with fuel pipe connector between fuel pipe and fuel pipe fitting. See Fig. 25 and Fig. 33 . Ensure hose, fuel pipe and fuel pipe connector are properly connected. Install fuel pipe clamp. 5. Install negative battery cable. Connect Toyota hand-held tester to data link connector No. 3 at driver's side of instrument panel. See Fig. 7 and Fig. 10 . Turn ignition on. DO NOT start engine. 6. Turn hand-held tester on. Select ACTIVE TEST MODE on hand-held tester. Using hand-held tester manufacturer's instructions, operate fuel pump and note fuel pressure. If hand-held tester is not available, fuel pump may also be activated by connecting battery voltage to specified terminals on fuel pump. See Fig. 17 and Fig. 20 . Fuel pressure should be 44-50 psi (3.1-3.5 kg/cm2 ). 7. If fuel pressure is within specification, go to next step. If fuel pressure exceeds specification, replace fuel pressure regulator mounted on fuel pump in the fuel tank. See FUEL PRESSURE REGULATOR under FUEL SYSTEMS in REMOVAL, OVERHAUL & INSTALLATION - 4-CYLINDER article. If fuel pressure is less than specified, check for leaking fuel hoses or connections, restricted fuel filter, defective fuel pump or defective fuel pressure regulator. 8. Turn ignition off. Remove hand-held tester. Start engine and allow engine to idle. Note fuel pressure with engine idling. Fuel pressure should be 44-50 psi (3.1-3.5 kg/cm2 ). 9. Shut engine off and note fuel pressure. Fuel pressure should remain at least 21 psi (1.5 kg/cm2 ) for a minimum of 5 minutes. If fuel pressure is within specification and holds as specified, go to next step. If fuel pressure is not within specification or does not hold as specified, check for defective fuel pump, fuel injector or fuel pressure regulator. 10. Release fuel pressure. Disconnect negative battery cable. Remove adapter, hose, fuel pressure gauge and fuel pipe connector. 11. Install fuel pipe on fuel pipe fitting. Pull on fuel pipe to ensure fuel pipe is properly locked on fuel pipe fitting. Reinstall fuel pipe clamp. Install negative battery cable. Check for fuel leaks by activating the fuel pump by using hand-held tester or connecting battery voltage to fuel pump.

2002 ENGINE PERFORMANCE Basic Diagnostic Procedures - 4-Cylinder

Fig. 35: Locating Fuel Pipe Clamp & Disconnecting Fuel Pipe From Fuel Pipe Fitting (RAV4) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Prius

WARNING: Read service precautions before proceeding with service procedure. See SERVICE PRECAUTIONS . 1. Ensure battery is fully charged. Release fuel pressure. See FUEL SYSTEM PRESSURE RELEASE . Disconnect negative battery cable. 2. Purchase fuel pipe (part No. 23901-21020) from parts department. Remove fuel pipe connector from end of NEW fuel pipe. See Fig. 23 . 3. Ensure area around fuel pipe at end of fuel rail and disconnect fitting is clean. See Fig. 36 . CAUTION: Use care when disconnecting fuel pipe, as some residual fuel pressure may still exist in the fuel system.

2002 ENGINE PERFORMANCE Basic Diagnostic Procedures - 4-Cylinder

4. Depress both sides of retainer and pull fuel pipe with disconnect fitting from fuel pipe fitting. See Fig. 36 . 5. Install Adapter (SST 09268-41250) and hose with fuel pressure gauge from Fuel Pressure Gauge Set (SST 09268-45014) with fuel pipe connector between fuel pipe and fuel pipe fitting. See Fig. 33 . Ensure hose, fuel pipe and fuel pipe connector are properly connected. 6. Install negative battery cable. Connect Toyota hand-held tester to data link connector No. 3 at driver's side of instrument panel. See Fig. 9 . Turn ignition on. DO NOT start engine. 7. Turn hand-held tester on. Select ACTIVE TEST MODE on hand-held tester. Using hand-held tester manufacturer's instructions, operate fuel pump and note fuel pressure. If hand-held tester is not available, fuel pump may also be activated by connecting battery voltage to specified terminals on fuel pump. See Fig. 19 . Fuel pressure should be 44-50 psi (3.1-3.5 kg/cm2 ). 8. If fuel pressure is within specification, go to next step. If fuel pressure exceeds specification, fuel pressure regulator is defective. Fuel pressure regulator is mounted on fuel pump in the fuel tank. It may be necessary to replace fuel pressure regulator, fuel pump and fuel tank as an assembly. Consult parts department for parts availability. If fuel pressure is less than specified, check for leaking fuel hoses or connections or defective fuel pump. 9. Turn ignition off. Remove hand-held tester. Start engine and allow engine to idle. Note fuel pressure with engine idling. Fuel pressure should be 44-50 psi (3.1-3.5 kg/cm2 ). 10. Shut engine off and note fuel pressure. Fuel pressure should remain at least 21 psi (1.5 kg/cm2 ) for a minimum of 5 minutes. If fuel pressure is within specification and holds as specified, go to next step. If fuel pressure is not within specification or does not hold as specified, check for defective fuel pump or defective fuel injector. 11. Release fuel pressure. Disconnect negative battery cable. Remove adapter, hose, fuel pressure gauge and fuel pipe connector. CAUTION: DO NOT reuse old retainer when installing fuel pipe on fuel pipe fitting. Always use a NEW retainer. 12. Apply light coat of engine oil on tip of fuel pipe fitting to allow for ease of disconnect fitting and fuel pipe installation. Using NEW retainer, install fuel pipe on fuel pipe fitting until "click" sound is heard. DO NOT reuse old retainer. Pull on fuel pipe to ensure fuel pipe is properly locked on fuel pipe fitting. 13. Install negative battery cable. Check for fuel leaks by activating the fuel pump by using hand-held tester or connecting battery voltage to fuel pump.

2002 ENGINE PERFORMANCE Basic Diagnostic Procedures - 4-Cylinder

Fig. 36: Locating Fuel Pipe, Disconnect Fitting & Disconnecting Fuel Pipe From Fuel Pipe Fitting (Prius) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Tacoma

1. Ensure battery is fully charged. Release fuel pressure. See FUEL SYSTEM PRESSURE RELEASE . Disconnect negative battery cable. 2. Note location for fuel pressure gauge installation on fuel rail. See Fig. 37 . Fuel pressure gauge is installed at firewall end of fuel rail, between fuel rail and fuel inlet pipe. Cover union bolt at fuel rail with shop towel. Remove union bolt with gaskets, and disconnect fuel inlet pipe from fuel rail. 3. Install fuel pressure gauge from Fuel Pressure Gauge Set (SST 09268-45014) with gaskets, fuel inlet pipe and union bolt on fuel rail. See Fig. 37 . Tighten union bolt to 21 ft. lbs. (29 N.m). 4. Reinstall negative battery cable. Connect Toyota hand-held tester to data link connector No. 3 at driver's side of instrument panel. See Fig. 11 . Turn ignition on. DO NOT start engine. 5. Turn hand-held tester on. Select ACTIVE TEST MODE on hand-held tester. Using hand-held tester manufacturer's instructions, operate fuel pump and note fuel pressure. If hand-held tester is not available, fuel pump may also be activated by connecting battery voltage to specified terminals on fuel pump. See Fig. 21 . Fuel pressure should be 38-44 psi (2.7-3.1 kg/cm2 ).

2002 ENGINE PERFORMANCE Basic Diagnostic Procedures - 4-Cylinder

6. If fuel pressure is within specification, go to next step. If fuel pressure exceeds specification, replace fuel pressure regulator mounted on fuel rail. See FUEL PRESSURE REGULATOR under FUEL SYSTEMS in REMOVAL, OVERHAUL & INSTALLATION - 4-CYLINDER article. If fuel pressure is less than specified, check for leaking fuel hoses or connections, restricted fuel filter, defective fuel pump or defective fuel pressure regulator. 7. Turn ignition off. Remove hand-held tester. Start engine and allow engine to idle. Note fuel pressure with engine idling. 8. Check vacuum hose routing for fuel pressure regulator mounted on fuel rail to determine if fuel pressure regulator is vacuum controlled. If vacuum hose is connected to engine vacuum and not vented to the air cleaner assembly, fuel pressure regulator is vacuum controlled. If vacuum hose is vented to air cleaner assembly and not to engine vacuum, fuel pressure regulator is not vacuum controlled. On models with vacuum controlled fuel pressure regulator, fuel pressure should be 31-37 psi (2.2-2.6 kg/cm2 ) with engine idling and vacuum applied, and 38-44 (2.7-3.1 psi 2.7-3.1 kg/cm2 ) without vacuum with engine idling. On models without vacuum controlled fuel pressure regulator, fuel pressure should be 38-44 psi (2.7-3.1 kg/cm2 ) with engine idling. On all models, if fuel pressure is within specification, go to next step. If fuel pressure is not within specification, check for defective vacuum hose (vacuum controlled fuel pressure regulator) or fuel pressure regulator. 9. Shut engine off and note fuel pressure. Fuel pressure should remain at least 21 psi (1.5 kg/cm2 ) for a minimum of 5 minutes. If fuel pressure is within specification and holds as specified, go to next step. If fuel pressure is not within specification or does not hold as specified, check for defective fuel pump, fuel injector or fuel pressure regulator. 10. Release fuel pressure. Disconnect negative battery cable. Remove fuel pressure gauge. Using NEW gaskets, reinstall fuel inlet pipe on fuel rail. Tighten union bolt to 21 ft. lbs. (29 N.m). Install negative battery cable. Check for fuel leaks by activating the fuel pump by using hand-held tester or connecting battery voltage to fuel pump.

2002 ENGINE PERFORMANCE Basic Diagnostic Procedures - 4-Cylinder

Fig. 37: Installing Fuel Pressure Gauge (Tacoma) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. FUEL PUMP CONTROL CIRCUIT NOTE: For information on testing relays and fuel system components, see SYSTEM & COMPONENT TESTING - 4-CYLINDER article. Circuit opening relay may also be identified by appropriate illustration in SYSTEM & COMPONENT TESTING - 4-CYLINDER article. For complete wiring circuit of electrical components on a specific model, see WIRING DIAGRAMS article. For additional testing information for fuel pump control circuit, see FUEL PUMP CONTROL CIRCUIT under COMPUTERIZED ENGINE CONTROLS in SYSTEM & COMPONENT TESTING - 4-CYLINDER article.

NOTE:

Circuit Opening Relay (Camry)

Circuit opening relay controls fuel pump circuit. When EFI main relay is energized, it provides battery voltage to one side of circuit opening relay. When ignition is turned on, voltage is supplied through IG2 fuse to other side of circuit opening relay. When proper input signals are delivered to Engine Control Module (ECM), circuit opening relay ground circuit is grounded at ECM terminal FC. Circuit opening relay then provides voltage to fuel pump for fuel pump operation. For circuit opening relay location, see CIRCUIT OPENING RELAY LOCATION table.
Circuit Opening Relay (Camry Solara & Highlander)

Circuit opening relay controls fuel pump circuit. When EFI main relay is energized, it provides battery voltage to one side of circuit opening relay. When ignition is turned on, voltage is supplied through IGN fuse to other side of circuit opening relay. When proper input signals are delivered to Engine Control Module (ECM), circuit opening relay ground circuit is grounded at ECM terminal FC. Circuit opening relay then provides voltage to fuel pump for fuel pump operation. For circuit opening relay location, see CIRCUIT OPENING RELAY LOCATION table.
Circuit Opening Relay (Celica, ECHO & Prius)

Circuit opening relay controls fuel pump circuit. When EFI main relay is energized, it provides battery voltage to both sides of circuit opening relay. When proper input signals are delivered to Engine Control Module (ECM), circuit opening relay ground circuit is grounded at ECM terminal FC. Circuit opening relay then provides voltage to fuel pump for fuel pump operation. For circuit opening relay location, see CIRCUIT OPENING RELAY LOCATION table.
Circuit Opening Relay (Corolla)

Circuit opening relay controls fuel pump circuit. When EFI main relay is energized, it provides battery voltage to both sides of circuit opening relay. EFI main relay may also be referred to as EFI relay or F-HTR relay. When proper input signals are delivered to Engine Control Module (ECM), circuit opening relay ground circuit is grounded at ECM terminal FC. Circuit opening relay then provides voltage to fuel pump for fuel pump operation. For circuit opening relay location, see CIRCUIT OPENING RELAY LOCATION table.
Circuit Opening Relay (MR2)

2002 ENGINE PERFORMANCE Basic Diagnostic Procedures - 4-Cylinder

Circuit opening relay controls fuel pump circuit. When EFI main relay is energized, it provides battery voltage to one side of circuit opening relay. When ignition is turned on, voltage is supplied from ignition switch to other side of circuit opening relay. When proper input signals are delivered to Engine Control Module (ECM), circuit opening relay ground circuit is grounded at ECM terminal FC. Circuit opening relay then provides voltage to fuel pump for fuel pump operation. For circuit opening relay location, see CIRCUIT OPENING RELAY LOCATION table.
Circuit Opening Relay (RAV4)

Circuit opening relay controls fuel pump circuit. When EFI main relay is energized, it provides battery voltage to one side of circuit opening relay. When ignition is turned on, voltage is supplied to other side of circuit opening relay from IG2 fuse. When proper input signals are delivered to Engine Control Module (ECM), circuit opening relay ground circuit is grounded at ECM terminal FC. Circuit opening relay then provides voltage to fuel pump for fuel pump operation. For circuit opening relay location, see CIRCUIT OPENING RELAY LOCATION table.
Circuit Opening Relay (Tacoma)

Circuit opening relay controls fuel pump circuit. When EFI main relay is energized, it provides battery voltage to one side of circuit opening relay. When ignition is turned on, voltage is supplied through IGN fuse to other side of circuit opening relay. When proper input signals are delivered to Engine Control Module (ECM), circuit opening relay ground circuit is grounded at ECM terminal FC. Circuit opening relay then provides voltage to fuel pump for fuel pump operation. For circuit opening relay location, see CIRCUIT OPENING RELAY LOCATION table. CIRCUIT OPENING RELAY LOCATION (1) Application Camry & Camry Solara
(2) Location

In Fuse/Relay Box At Driver's Side Front Corner Of Engine Compartment Celica In Fuse/Relay Box At Driver's Side Front Corner Of Engine Compartment, Just In Front Of Strut Tower Corolla Center Relay In Relay Box Behind Driver's Side Kick Panel ECHO In Fuse/Relay Box Behind Driver's Side Of Instrument Panel Highlander In Relay Box Just Above Driver's Side Kick Panel MR2 In Relay Box On Firewall At Driver's Side Front Corner Of Engine Compartment Prius & RAV4 In Fuse/Relay Box At Driver's Side Front Corner Of Engine Compartment Tacoma Behind Lower Instrument Panel Cover, Next To Driver's Side Of Steering Column (1) Circuit opening relay may be marked as CIR OPN relay.
(2) Circuit opening relay may also be identified by appropriate illustration in SYSTEM &

COMPONENT TESTING - 4-CYLINDER article.

EFI Main Relay (Camry & Camry Solara)

EFI main relay may also be referred to as EFI relay. EFI fuse supplies constant battery voltage to one side of EFI main relay. EFI main relay is energized by MREL terminal of Engine Control Module (ECM). When

2002 ENGINE PERFORMANCE Basic Diagnostic Procedures - 4-Cylinder

EFI main relay is energized, EFI main relay provides battery voltage to circuit opening relay, +B terminal of ECM and various other electrical components. For EFI main relay location, see EFI MAIN RELAY LOCATION table.
EFI Main Relay (Celica)

EFI main relay may also be referred to as EFI relay. EFI fuse supplies constant battery voltage to one side of EFI main relay. EFI main relay is energized by MREL terminal of Engine Control Module (ECM). When EFI main relay is energized, EFI main relay provides battery voltage to circuit opening relay, +B terminal of ECM, EFI No. 1 and 2 fuses, and various other electrical components. For EFI main relay location, see EFI MAIN RELAY LOCATION table.
EFI Main Relay (Corolla)

EFI main relay may also be referred to as EFI relay or F-HTR relay. EFI fuse supplies constant battery voltage to one side of EFI main relay. EFI fuse may also be referred to as F-HTR fuse. When ignition is turned on, voltage is supplied through IGN fuse to other side of EFI main relay. EFI main relay is then energized and provides battery voltage to circuit opening relay, +B terminal of Engine Control Module (ECM) and various other electrical components. For EFI main relay location, see EFI MAIN RELAY LOCATION table.
EFI Main Relay (ECHO)

EFI main relay may also be referred to as EFI relay. EFI fuse supplies constant battery voltage to one side of EFI main relay. When ignition is turned on, voltage is supplied to other side of EFI main relay. EFI main relay is then energized and provides battery voltage to circuit opening relay, +B terminal of Engine Control Module (ECM) and various other electrical components. For EFI main relay location, see EFI MAIN RELAY LOCATION table.
EFI Main Relay (Highlander)

EFI main relay may also be referred to as EFI relay. EFI fuse supplies constant battery voltage to one side of EFI main relay. EFI main relay is energized by MREL terminal of Engine Control Module (ECM). When EFI main relay is energized, EFI main relay provides battery voltage to circuit opening relay, +B terminal of ECM and various other electrical components. For EFI main relay location, see EFI MAIN RELAY LOCATION table.
EFI Main Relay (MR2)

EFI main relay may also be referred to as EFI relay. EFI No. 1 fuse supplies constant battery voltage to one side of EFI main relay. EFI main relay is energized by MREL terminal of Engine Control Module (ECM). When EFI main relay is energized, EFI main relay provides battery voltage to circuit opening relay, +B terminal of ECM and various other electrical components. For EFI main relay location, see EFI MAIN RELAY LOCATION table.
EFI Main Relay (Prius)

EFI main relay may also be referred to as EFI relay. EFI fuse supplies constant battery voltage to one side of EFI main relay. EFI main relay is energized by MREL terminal of Engine Control Module (ECM). When EFI main relay is energized, EFI main relay provides battery voltage to circuit opening relay, +B terminal of ECM and various other electrical components. For EFI main relay location, see EFI MAIN RELAY LOCATION table.

2002 ENGINE PERFORMANCE Basic Diagnostic Procedures - 4-Cylinder

EFI Main Relay (RAV4)

EFI main relay may also be referred to as EFI relay. EFI No. 2 fuse supplies constant battery voltage to one side of EFI main relay. EFI main relay is energized by MREL terminal of Engine Control Module (ECM). When EFI main relay is energized, EFI main relay provides battery voltage to circuit opening relay, A/F heater relay, +B terminal of ECM and various other electrical components. For EFI main relay location, see EFI MAIN RELAY LOCATION table.
EFI Main Relay (Tacoma)

EFI main relay may also be referred to as EFI relay. EFI fuse supplies constant battery voltage to one side of EFI main relay. When ignition is turned on, voltage is supplied through IGN fuse to other side of EFI main relay. EFI main relay is then energized and provides battery voltage to circuit opening relay, +B terminal of Engine Control Module (ECM) and various other electrical components. For EFI main relay location, see EFI MAIN RELAY LOCATION table. EFI MAIN RELAY LOCATION Application Camry & Camry Solara Celica, Corolla ECHO & Highlander MR2 Prius, RAV4 & Tacoma

Location In Fuse/Relay Box At Driver's Side Front Corner Of Engine Compartment In Fuse/Relay Box At Driver's Side Front Corner Of Engine Compartment, Just In Front Of Strut Tower In Relay Box On Firewall At Driver's Side Front Corner Of Engine Compartment In Fuse/Relay Box At Driver's Side Front Corner Of Engine Compartment

IGNITION SYSTEMS
NOTE: SPARK TEST NOTE: On Camry, Camry Solara, Highlander, MR2 and RAV4, an engine immobilizer system may be used. When performing spark test, it may be necessary to substitute or replace Engine Control Module (ECM). On models with engine immobilizer system, if ECM is replaced, ECM must be programmed with proper ignition key code for engine immobilizer system. Models equipped with engine immobilizer system may be identified by looking at the ignition key. On models equipped with engine immobilizer system, the top of the ignition key is thicker than a standard ignition key, as a transponder chip is incorporated into the top of the ignition key. For programming procedures, see COMPUTER RELEARN PROCEDURES article in GENERAL INFORMATION, or appropriate ENGINE IMMOBILIZER SYSTEMS article in ACCESSORIES & EQUIPMENT. All models use a distributorless ignition system.

Camry, Camry Solara Celica, Corolla & ECHO

1. Remove No. 2 cylinder head cover located on top of engine, above ignition coils and valve cover.

2002 ENGINE PERFORMANCE Basic Diagnostic Procedures - 4-Cylinder

Disconnect electrical connectors at ignition coils located on top of valve cover. Remove retaining bolts and ignition coils from valve cover. Remove spark plugs. Install spark plug on each ignition coil. Reinstall electrical connectors on ignition coils. CAUTION: To prevent gasoline from being injected, electrical connectors should be disconnected from fuel injectors. DO NOT crank engine for longer than 5 seconds when checking for spark. 2. Disconnect electrical connectors at fuel injectors. Ground spark plugs against cylinder block. Crank engine and check for spark. Spark test is based on the assumption that spark plugs are okay. If spark does not exist, go to next step. If spark exists, reinstall components. On Camry and Camry Solara, tighten spark plugs to 14 ft. lbs. (19 N.m) and ignition coil retaining bolts to 80 INCH lbs. (9.0 N.m). On Celica and ECHO, install and tighten spark plugs to 13 ft. lbs. (18 N.m) and ignition coil retaining bolts to 80 INCH lbs. (9.0 N.m). On Corolla, install and tighten spark plugs to 13 ft. lbs. (18 N.m) and ignition coil retaining bolts to 62 INCH lbs. (7.0 N.m). 3. Check ignition coil electrical connections. If electrical connections are okay, go to next step. If electrical connections are defective, repair as necessary and recheck for spark. 4. Install different ignition coil on spark plug and recheck for spark. If spark still does not exist, go to next step. If spark now exists with different ignition coil, replace original ignition coil. Reinstall components. On Camry and Camry Solara, tighten spark plugs to 14 ft. lbs. (19 N.m) and ignition coil retaining bolts to 80 INCH lbs. (9.0 N.m). On Celica and ECHO, install and tighten spark plugs to 13 ft. lbs. (18 N.m) and ignition coil retaining bolts to 80 INCH lbs. (9.0 N.m). On Corolla, install and tighten spark plugs to 13 ft. lbs. (18 N.m) and ignition coil retaining bolts to 62 INCH lbs. (7.0 N.m). 5. Turn ignition on. Using voltmeter, check for battery voltage at ignition coil positive terminal. See IGNITION COIL POSITIVE TERMINAL IDENTIFICATION table. If battery voltage exists, go to next step. If battery voltage does not exist, check wiring between ignition switch and ignition coil. See WIRING DIAGRAMS article. NOTE: On Celica, it may be necessary to check operation of IG2 relay by using wiring diagram. See WIRING DIAGRAMS article. IG2 fuse supplies constant battery voltage to one side of IG2 relay. When ignition is turned on, voltage is supplied from ignition switch to other side of IG2 relay and IG2 relay is then energized. When IG2 relay is energized, IG2 relay provides battery voltage to ignition coils and fuel injectors. IG2 fuse and IG2 relay are located in fuse/relay box at driver's side front corner of engine compartment, just in front of strut tower.

IGNITION COIL POSITIVE TERMINAL IDENTIFICATION Application Wire Color Camry & Camry Solara Black/Red Celica Black Corolla Black/White ECHO Black/Red 6. Check resistance of camshaft position sensor. See CAMSHAFT POSITION SENSOR . If camshaft position sensor resistance is within specification, go to next step. If camshaft position sensor resistance is not within specification, replace camshaft position sensor. See CAMSHAFT POSITION SENSOR under IGNITION SYSTEMS in REMOVAL, OVERHAUL & INSTALLATION - 4CYLINDER article.

2002 ENGINE PERFORMANCE Basic Diagnostic Procedures - 4-Cylinder

7. Check resistance of crankshaft position sensor. See CRANKSHAFT POSITION SENSOR . If crankshaft position sensor resistance is within specification, go to next step. If crankshaft position sensor resistance is not within specification, replace crankshaft position sensor. See CRANKSHAFT POSITION SENSOR under IGNITION SYSTEMS in REMOVAL, OVERHAUL & INSTALLATION - 4-CYLINDER article. 8. Check ignition IGT signal from Engine Control Module (ECM) to ignition coil. If ignition IGT signal from ECM is defective, Diagnostic Trouble Code (DTC) P1300, P1305, P1310 or P1315 will be set in ECM memory to indicate an ignitor circuit malfunction. See TESTING PROCEDURE under SELFDIAGNOSTIC SYSTEM in appropriate SELF-DIAGNOSTICS article for retrieving of DTCs. 9. If ignition IGT signal is okay, substitute another ignition coil and recheck system operation. If ignition IGT signal is defective, check wiring between ECM and ignition coil. See ENGINE CONTROL MODULE LOCATION table. See WIRING DIAGRAMS article. If wiring is defective, repair wiring as necessary and recheck system operation. If wiring is okay, substitute another ECM and recheck system operation. Reinstall components. On Camry and Camry Solara, tighten spark plugs to 14 ft. lbs. (19 N.m) and ignition coil retaining bolts to 80 INCH lbs. (9.0 N.m). On Celica and ECHO, install and tighten spark plugs to 13 ft. lbs. (18 N.m) and ignition coil retaining bolts to 80 INCH lbs. (9.0 N.m). On Corolla, install and tighten spark plugs to 13 ft. lbs. (18 N.m) and ignition coil retaining bolts to 62 INCH lbs. (7.0 N.m).
Highlander

1. Check for any Diagnostic Trouble Codes (DTC). See TESTING PROCEDURE under SELFDIAGNOSTIC SYSTEM in appropriate SELF-DIAGNOSTICS article for retrieving of DTCs. If no DTCs exist, go to next step. If any DTCs exist, perform service procedure for DTC. 2. Remove No. 2 cylinder head cover located on top of engine, above ignition coils and valve cover. Disconnect electrical connectors at ignition coils located on top of valve cover. Remove retaining bolts and ignition coils from valve cover. Remove spark plugs. Install spark plug on each ignition coil. Reinstall electrical connectors on ignition coils. CAUTION: To prevent gasoline from being injected, electrical connectors should be disconnected from fuel injectors. DO NOT crank engine for longer than 2 seconds when checking for spark. 3. Disconnect electrical connectors at fuel injectors. Ground spark plugs against cylinder block. Crank engine and check for spark. If spark exists only at some spark plugs and not at other spark plugs, go to next step. If spark does not exist at any spark plug, go to step 5 . If spark exists at all spark plugs, reinstall components. Tighten spark plugs to 14 ft. lbs. (19 N.m) and ignition coil retaining bolts to 80 INCH lbs. (9.0 N.m). 4. Install substitute spark plug for spark plug which did not fire and recheck for spark. If spark now exists, replace original spark plug. If spark still does not exist, replace ignition coil. Reinstall components. Tighten spark plugs to 14 ft. lbs. (19 N.m) and ignition coil retaining bolts to 80 INCH lbs. (9.0 N.m). 5. Install substitute spark plugs and recheck for spark. If spark now exists, replace original spark plugs. If spark still does not exist, replace ignition coil that does not produce spark. Reinstall components. Tighten spark plugs to 14 ft. lbs. (19 N.m) and ignition coil retaining bolts to 80 INCH lbs. (9.0 N.m).
MR2

1. Remove suspension upper braces. Suspension upper brace fits between firewall and top of each strut

2002 ENGINE PERFORMANCE Basic Diagnostic Procedures - 4-Cylinder

tower. Remove No. 2 cylinder head cover located on top of engine, above ignition coils and valve cover. Disconnect electrical connectors at ignition coils mounted on valve cover. Remove retaining bolts and ignition coils from valve cover. Remove spark plugs. Install spark plug on each ignition coil. Reinstall electrical connectors on ignition coils. CAUTION: To prevent gasoline from being injected, electrical connectors should be disconnected from fuel injectors. DO NOT crank engine for longer than 5 seconds when checking for spark. 2. Disconnect electrical connectors at fuel injectors. Ground spark plugs against cylinder block. Crank engine and check for spark. Spark test is based on the assumption that spark plugs are okay. If spark does not exist, go to next step. If spark exists, reinstall components. Tighten spark plugs to 19 ft. lbs. (26 N.m), ignition coil retaining bolts to 80 INCH lbs. (9.0 N.m) and suspension upper brace nuts to 59 ft. lbs. (80 N.m). 3. Check ignition coil electrical connections. If electrical connections are okay, go to next step. If electrical connections are defective, repair as necessary and recheck for spark. 4. Install different ignition coil on spark plug and recheck for spark. If spark still does not exist, go to next step. If spark now exists with different ignition coil, replace original ignition coil. Reinstall components. Tighten spark plugs to 19 ft. lbs. (26 N.m), ignition coil retaining bolts to 80 INCH lbs. (9.0 N.m) and suspension upper brace nuts to 59 ft. lbs. (80 N.m). 5. Turn ignition on. Using voltmeter, check for battery voltage at ignition coil positive terminal (Black/Red wire). If battery voltage exists, go to next step. If battery voltage does not exist, check wiring between IG2 relay and ignition coil. See WIRING DIAGRAMS article. IG2 fuse supplies constant battery voltage to one side of IG2 relay. When ignition is turned on, voltage is supplied from ignition switch to other side of IG2 relay and IG2 relay is then energized. When IG2 relay is energized, IG2 relay provides battery voltage to ignition coils and fuel injectors. If necessary to check operation of IG2 relay, see IG2 RELAY under MODULES, MOTORS, RELAYS & SOLENOIDS in SYSTEM & COMPONENT TESTING - 4-CYLINDER article. IG2 fuse is located in fuse/relay box at driver's side rear corner of engine compartment, just in front of strut tower. IG2 relay is located in relay box on firewall at driver's side front corner of engine compartment. 6. Check resistance of camshaft position sensor. See CAMSHAFT POSITION SENSOR . If camshaft position sensor resistance is within specification, go to next step. If camshaft position sensor resistance is not within specification, replace camshaft position sensor. See CAMSHAFT POSITION SENSOR under IGNITION SYSTEMS in REMOVAL, OVERHAUL & INSTALLATION - 4CYLINDER article. 7. Check resistance of crankshaft position sensor. See CRANKSHAFT POSITION SENSOR . If crankshaft position sensor resistance is within specification, go to next step. If crankshaft position sensor resistance is not within specification, replace crankshaft position sensor. See CRANKSHAFT POSITION SENSOR under IGNITION SYSTEMS in REMOVAL, OVERHAUL & INSTALLATION - 4-CYLINDER article. 8. Check ignition IGT signal from Engine Control Module (ECM) to ignition coil. If ignition IGT signal from ECM is defective, Diagnostic Trouble Code (DTC) P1300, P1305, P1310 or P1315 will be set in ECM memory to indicate an ignitor circuit malfunction. See TESTING PROCEDURE under SELFDIAGNOSTIC SYSTEM in appropriate SELF-DIAGNOSTICS article for retrieving of DTCs. 9. If ignition IGT signal is okay, substitute another ignition coil and recheck system operation. If ignition IGT signal is defective, check wiring between ECM and ignition coil. See ENGINE CONTROL MODULE LOCATION table. See WIRING DIAGRAMS article. If wiring is defective, repair wiring as necessary and recheck system operation. If wiring is okay, substitute another ECM and recheck system operation. Reinstall components. Tighten spark plugs to 19 ft. lbs. (26 N.m), ignition

2002 ENGINE PERFORMANCE Basic Diagnostic Procedures - 4-Cylinder

coil retaining bolts to 80 INCH lbs. (9.0 N.m) and suspension upper brace nuts to 59 ft. lbs. (80 N.m).
Prius

WARNING: Read service precautions before proceeding with service procedure. See SERVICE PRECAUTIONS . 1. Remove air cleaner assembly for access to ignition coils located on top of valve cover. Disconnect electrical connectors at ignition coils. Remove retaining bolts and ignition coils from valve cover. Remove spark plugs. Install spark plug on each ignition coil. Reinstall electrical connectors on ignition coils. CAUTION: To prevent gasoline from being injected, electrical connectors should be disconnected from fuel injectors. DO NOT crank engine for longer than 5 seconds when checking for spark. 2. Disconnect electrical connectors at fuel injectors. Ground spark plugs against cylinder block. Crank engine and check for spark. Spark test is based on the assumption that spark plugs are okay. If spark does not exist, go to next step. If spark exists, reinstall components. Tighten spark plugs to 13 ft. lbs. (18 N.m) and ignition coil retaining bolts to 80 INCH lbs. (9.0 N.m). 3. Check ignition coil electrical connections. If electrical connections are okay, go to next step. If electrical connections are defective, repair as necessary and recheck for spark. 4. Install different ignition coil on spark plug and recheck for spark. If spark still does not exist, go to next step. If spark now exists with different ignition coil, replace original ignition coil. Reinstall components. Tighten spark plugs to 13 ft. lbs. (18 N.m) and ignition coil retaining bolts to 80 INCH lbs. (9.0 N.m). 5. Turn ignition on. Using voltmeter, check for battery voltage at ignition coil positive terminal (Black/White wire). If battery voltage exists, go to next step. If battery voltage does not exist, check wiring between IG2 relay and ignition coil. See WIRING DIAGRAMS article. AM2 fuse supplies constant battery voltage to one side of IG2 relay. When ignition is turned on, voltage is supplied from ignition switch to other side of IG2 relay and IG2 relay is then energized. When IG2 relay is energized, IG2 relay provides battery voltage to ignition coils and fuel injectors. If necessary to check operation of IG2 relay, consult wiring diagram for relay testing. See WIRING DIAGRAMS article. AM2 fuse and IG2 relay are located in fuse/relay box at driver's side front corner of engine compartment. 6. Check resistance of camshaft position sensor. See CAMSHAFT POSITION SENSOR . If camshaft position sensor resistance is within specification, go to next step. If camshaft position sensor resistance is not within specification, replace camshaft position sensor. See CAMSHAFT POSITION SENSOR under IGNITION SYSTEMS in REMOVAL, OVERHAUL & INSTALLATION - 4CYLINDER article. 7. Check resistance of crankshaft position sensor. See CRANKSHAFT POSITION SENSOR . If crankshaft position sensor resistance is within specification, go to next step. If crankshaft position sensor resistance is not within specification, replace crankshaft position sensor. See CRANKSHAFT POSITION SENSOR under IGNITION SYSTEMS in REMOVAL, OVERHAUL & INSTALLATION - 4-CYLINDER article. 8. Check ignition IGT signal from Engine Control Module (ECM) to ignition coil. If ignition IGT signal from ECM is defective, Diagnostic Trouble Code (DTC) P1300, P1305, P1310 or P1315 will be set in ECM memory to indicate an ignitor circuit malfunction. See TESTING PROCEDURE under SELF-

2002 ENGINE PERFORMANCE Basic Diagnostic Procedures - 4-Cylinder

DIAGNOSTIC SYSTEM in appropriate SELF-DIAGNOSTICS article for retrieving of DTCs. 9. If ignition IGT signal is okay, substitute another ignition coil and recheck system operation. If ignition IGT signal is defective, check wiring between ECM and ignition coil. See ENGINE CONTROL MODULE LOCATION table. See WIRING DIAGRAMS article. If wiring is defective, repair wiring as necessary and recheck system operation. If wiring is okay, substitute another ECM and recheck system operation. Reinstall components. Tighten spark plugs to 13 ft. lbs. (18 N.m) and ignition coil retaining bolts to 80 INCH lbs. (9.0 N.m).
RAV4

1. Remove air cleaner assembly for access to ignition coils located on top of valve cover. Disconnect electrical connectors at ignition coils. Remove retaining bolts and ignition coils from valve cover. Remove spark plugs. Install spark plug on each ignition coil. Reinstall electrical connectors on ignition coils. CAUTION: To prevent gasoline from being injected, electrical connectors should be disconnected from fuel injectors. DO NOT crank engine for longer than 5 seconds when checking for spark. 2. Disconnect electrical connectors at fuel injectors. Ground spark plugs against cylinder block. Crank engine and check for spark. Spark test is based on the assumption that spark plugs are okay. If spark does not exist, go to next step. If spark exists, reinstall components. Tighten spark plugs to 14 ft. lbs. (19 N.m) and ignition coil retaining bolts to 80 INCH lbs. (9.0 N.m). 3. Check ignition coil electrical connections. If electrical connections are okay, go to next step. If electrical connections are defective, repair as necessary and recheck for spark. 4. Install different ignition coil on spark plug and recheck for spark. If spark still does not exist, go to next step. If spark now exists with different ignition coil, replace original ignition coil. Reinstall components. Tighten spark plugs to 14 ft. lbs. (19 N.m) and ignition coil retaining bolts to 80 INCH lbs. (9.0 N.m). 5. Turn ignition on. Using voltmeter, check for battery voltage at ignition coil positive terminal (Black/White wire). If battery voltage exists, go to next step. If battery voltage does not exist, check wiring between IG2 relay and ignition coil. See WIRING DIAGRAMS article. IGN fuse supplies constant battery voltage to one side of IG2 relay. When ignition is turned on, voltage is supplied from ignition switch, through IG2 fuse and to other side of IG2 relay and IG2 relay is then energized. When IG2 relay is energized, IG2 relay provides battery voltage to ignition coils and fuel injectors. If necessary to check operation of IG2 relay, see IG2 RELAY under MODULES, MOTORS, RELAYS & SOLENOIDS in SYSTEM & COMPONENT TESTING - 4-CYLINDER article. IGN fuse and IG2 relay are located in fuse/relay box at driver's side front corner of engine compartment. IG2 fuse is located in fuse box behind driver's side of instrument panel. 6. Check resistance of camshaft position sensor. See CAMSHAFT POSITION SENSOR . If camshaft position sensor resistance is within specification, go to next step. If camshaft position sensor resistance is not within specification, replace camshaft position sensor. See CAMSHAFT POSITION SENSOR under IGNITION SYSTEMS in REMOVAL, OVERHAUL & INSTALLATION - 4CYLINDER article. 7. Check resistance of crankshaft position sensor. See CRANKSHAFT POSITION SENSOR . If crankshaft position sensor resistance is within specification, go to next step. If crankshaft position sensor resistance is not within specification, replace crankshaft position sensor. See CRANKSHAFT POSITION SENSOR under IGNITION SYSTEMS in REMOVAL, OVERHAUL & INSTALLATION - 4-CYLINDER article.

2002 ENGINE PERFORMANCE Basic Diagnostic Procedures - 4-Cylinder

8. Check ignition IGT signal from Engine Control Module (ECM) to ignition coil. If ignition IGT signal from ECM is defective, Diagnostic Trouble Code (DTC) P1300, P1305, P1310 or P1315 will be set in ECM memory to indicate an ignitor circuit malfunction. See TESTING PROCEDURE under SELFDIAGNOSTIC SYSTEM in appropriate SELF-DIAGNOSTICS article for retrieving of DTCs. 9. If ignition IGT signal is okay, substitute another ignition coil and recheck system operation. If ignition IGT signal is defective, check wiring between ECM and ignition coil. See ENGINE CONTROL MODULE LOCATION table. See WIRING DIAGRAMS article. If wiring is defective, repair wiring as necessary and recheck system operation. If wiring is okay, substitute another ECM and recheck system operation. Reinstall components. Tighten spark plugs to 14 ft. lbs. (19 N.m) and ignition coil bolts to 80 INCH lbs. (9.0 N.m).
Tacoma

1. Remove necessary components for access to ignition coils located on top of valve cover. Disconnect electrical connectors at ignition coils. Remove retaining bolts and ignition coils from valve cover. Remove spark plugs. Install spark plug on each ignition coil. Reinstall electrical connectors on ignition coils. CAUTION: To prevent gasoline from being injected, DO NOT crank engine for longer than 2 seconds when checking for spark. 2. Ground spark plugs against cylinder block. Crank engine and check for spark. Spark test is based on the assumption that spark plugs are okay. If spark does not exist, go to next step. If spark exists, reinstall components. Tighten spark plugs to 15 ft. lbs. (20 N.m) and ignition coil retaining bolts to 66 INCH lbs. (7.5 N.m). 3. Check ignition coil electrical connections. If electrical connections are okay, go to next step. If electrical connections are defective, repair as necessary and recheck for spark. 4. Install different ignition coil on spark plug and recheck for spark. If spark still does not exist, go to next step. If spark now exists with different ignition coil, replace original ignition coil. Reinstall components. Tighten spark plugs to 15 ft. lbs. (20 N.m) and ignition coil retaining bolts to 66 INCH lbs. (7.5 N.m). 5. Turn ignition on. Using voltmeter, check for battery voltage at ignition coil positive terminal (Black/Red wire). If battery voltage exists, go to next step. If battery voltage does not exist, check Black/Red wire between ignition switch and ignition coil. See WIRING DIAGRAMS article. 6. Check resistance of camshaft position sensor. See CAMSHAFT POSITION SENSOR . If camshaft position sensor resistance is within specification, go to next step. If camshaft position sensor resistance is not within specification, replace camshaft position sensor. See CAMSHAFT POSITION SENSOR under IGNITION SYSTEMS in REMOVAL, OVERHAUL & INSTALLATION - 4CYLINDER article. 7. Check resistance of crankshaft position sensor. See CRANKSHAFT POSITION SENSOR . If crankshaft position sensor resistance is within specification, go to next step. If crankshaft position sensor resistance is not within specification, replace crankshaft position sensor. See CRANKSHAFT POSITION SENSOR under IGNITION SYSTEMS in REMOVAL, OVERHAUL & INSTALLATION - 4-CYLINDER article. 8. Check ignition IGT signal from Engine Control Module (ECM) to ignition coil. If ignition IGT signal from ECM is defective, Diagnostic Trouble Code (DTC) P1300, P1305, P1310 or P1315 will be set in ECM memory to indicate an ignitor circuit malfunction. See TESTING PROCEDURE under SELFDIAGNOSTIC SYSTEM in appropriate SELF-DIAGNOSTICS article for retrieving of DTCs.

2002 ENGINE PERFORMANCE Basic Diagnostic Procedures - 4-Cylinder

9. If ignition IGT signal is okay, substitute another ignition coil and recheck system operation. If ignition IGT signal is defective, check wiring between ECM and ignition coil. See ENGINE CONTROL MODULE LOCATION table. See WIRING DIAGRAMS article. If wiring is defective, repair wiring as necessary and recheck system operation. If wiring is okay, substitute another ECM and recheck system operation. Reinstall components. Tighten spark plugs to 15 ft. lbs. (20 N.m) and ignition coil retaining bolts to 66 INCH lbs. (7.5 N.m). ENGINE CONTROL MODULE LOCATION Model Camry & Camry Solara Celica
(1) Location

Behind Glove Box In Engine Compartment, Below Cover, Just In Front Of Battery, Next To Driver's Side Strut Tower Corolla Behind Stereo On Instrument Panel, Just In Front Of Center Console ECHO & Highlander Behind Glove Box MR2 On Inside Of Firewall, Directly Behind Driver's Seat & Luggage Compartment Prius Behind Glove Box RAV4 Near Passenger's Side Kick Panel, Just Below Instrument Panel Tacoma Behind Glove Box (1) For illustration of ECM location, see THEORY & OPERATION article. CAMSHAFT POSITION SENSOR
Camry, Camry Solara, ECHO & Highlander

1. Camshaft position sensor may also be referred to Variable Valve Timing (VVT) sensor. Disconnect electrical connector at camshaft position sensor. Camshaft position sensor is located on end of cylinder head at flywheel end of engine, just at end of intake camshaft. See Fig. 38 and Fig. 39 . Using ohmmeter, check resistance between electrical terminals on camshaft position sensor. 2. Ensure camshaft position sensor resistance is within specification. See CAMSHAFT POSITION SENSOR RESISTANCE table. Replace camshaft position sensor if resistance is not within specification. See CAMSHAFT POSITION SENSOR under IGNITION SYSTEMS in REMOVAL, OVERHAUL & INSTALLATION - 4-CYLINDER article. Reinstall electrical connector on camshaft position sensor.
Celica & Corolla

1. Camshaft position sensor may also be referred to Variable Valve Timing (VVT) sensor. Disconnect electrical connector at camshaft position sensor. Camshaft position sensor is located just above intake manifold on cylinder head, at flywheel end of engine. See Fig. 40 and Fig. 41 . Using ohmmeter,

2002 ENGINE PERFORMANCE Basic Diagnostic Procedures - 4-Cylinder

check resistance between electrical terminals on camshaft position sensor. 2. Ensure camshaft position sensor resistance is within specification. See CAMSHAFT POSITION SENSOR RESISTANCE table. Replace camshaft position sensor if resistance is not within specification. See CAMSHAFT POSITION SENSOR under IGNITION SYSTEMS in REMOVAL, OVERHAUL & INSTALLATION - 4-CYLINDER article. Reinstall electrical connector on camshaft position sensor.
MR2

1. Camshaft position sensor may also be referred to Variable Valve Timing (VVT) sensor. Camshaft position sensor is located just above intake manifold on cylinder head, at flywheel end of engine. See Fig. 42 . 2. Manufacturer recommends removing camshaft position sensor from cylinder head before checking the resistance. Remove camshaft position sensor. See CAMSHAFT POSITION SENSOR under IGNITION SYSTEMS in REMOVAL, OVERHAUL & INSTALLATION - 4-CYLINDER article. 3. Using ohmmeter, check resistance between electrical terminals on camshaft position sensor. Ensure camshaft position sensor resistance is within specification. See CAMSHAFT POSITION SENSOR RESISTANCE table. Replace camshaft position sensor if resistance is not within specification. Reinstall camshaft position sensor.
Prius & RAV4

WARNING: On Prius, read service precautions before proceeding with service procedure. See SERVICE PRECAUTIONS . 1. Camshaft position sensor may also be referred to Variable Valve Timing (VVT) sensor. Disconnect electrical connector at camshaft position sensor. Camshaft position sensor is located on end of cylinder head at flywheel end of engine. See Fig. 43 and Fig. 44 . Using ohmmeter, check resistance between electrical terminals on camshaft position sensor. 2. Ensure camshaft position sensor resistance is within specification. See CAMSHAFT POSITION SENSOR RESISTANCE table. Replace camshaft position sensor if resistance is not within specification. See CAMSHAFT POSITION SENSOR under IGNITION SYSTEMS in REMOVAL, OVERHAUL & INSTALLATION - 4-CYLINDER article. Reinstall electrical connector on camshaft position sensor.
Tacoma

1. Disconnect electrical connector at camshaft position sensor. Camshaft position sensor is located on cylinder head, just in front of intake manifold. See Fig. 45 . Using ohmmeter, check resistance between electrical terminals on camshaft position sensor. 2. Ensure camshaft position sensor resistance is within specification. See CAMSHAFT POSITION SENSOR RESISTANCE table. Replace camshaft position sensor if resistance is not within specification. See CAMSHAFT POSITION SENSOR under IGNITION SYSTEMS in REMOVAL, OVERHAUL & INSTALLATION - 4-CYLINDER article. Reinstall electrical connector on camshaft position sensor. CAMSHAFT POSITION SENSOR RESISTANCE Application Camry, Camry Solara, Celica, Corolla, Highlander, MR2, RAV4 & Tacoma

Ohms

2002 ENGINE PERFORMANCE Basic Diagnostic Procedures - 4-Cylinder

Cold (1) Hot (2) ECHO & Prius Cold (1) Hot (2) (1) Cold is with temperature of 14-122F (-10-50C).
(2) Hot is with temperature of 122-212F (50-100C).

835-1400 1060-1645 1630-2740 2065-3225

Fig. 38: Locating Camshaft Position Sensor (Camry, Camry Solara & Highlander) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 ENGINE PERFORMANCE Basic Diagnostic Procedures - 4-Cylinder

Fig. 39: Locating & Testing Camshaft Position Sensor (ECHO) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 40: Locating & Testing Camshaft Position Sensor (Celica 1.8L 1ZZ-FE & Corolla) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 ENGINE PERFORMANCE Basic Diagnostic Procedures - 4-Cylinder

within specification. See CRANKSHAFT POSITION SENSOR under IGNITION SYSTEMS in REMOVAL, OVERHAUL & INSTALLATION - 4-CYLINDER article. Reinstall crankshaft position sensor electrical connector.
Tacoma

1. Crankshaft position sensor is located near crankshaft pulley, just above oil pan on driver's side of engine. See Fig. 52 . 2. Manufacturer recommends removing crankshaft position sensor before checking the resistance. See CRANKSHAFT POSITION SENSOR under IGNITION SYSTEMS in REMOVAL, OVERHAUL & INSTALLATION - 4-CYLINDER article. 3. Using ohmmeter, check resistance between NE- and NE+ terminals on crankshaft position sensor. See Fig. 52 . Replace crankshaft position sensor if resistance is not within specification. See CRANKSHAFT POSITION SENSOR RESISTANCE table. Reinstall crankshaft position sensor. CRANKSHAFT POSITION SENSOR RESISTANCE Application Camry & Camry Solara Cold (1) Hot (2) Celica & Corolla Cold (1) Hot (2) ECHO & Highlander Cold (1) Hot (2) MR2 Cold (1) Hot (2) Prius & RAV4 Cold (1) Hot (2) Tacoma Cold (1) Hot (2) (1) Cold is with temperature of 14-122F (-10-50C).
(2) Hot is with temperature of 122-212F (50-100C).

Ohms 985-1600 1265-1890 1630-2740 2065-3225 985-1600 1265-1890 1630-2740 2065-3225 985-1600 1265-1890 1630-2740 2065-3225

2002 ENGINE PERFORMANCE Basic Diagnostic Procedures - 4-Cylinder

Fig. 47: Locating Crankshaft Position Sensor (Celica & Corolla) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 48: Locating & Checking Crankshaft Position Sensor (ECHO) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 ENGINE PERFORMANCE Basic Diagnostic Procedures - 4-Cylinder

Fig. 52: Locating & Checking Crankshaft Position Sensor (Tacoma) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. IGNITION COIL RESISTANCE
All Models

Ignition coil testing procedure and resistance are not available from manufacturer.

IDLE SPEED & IGNITION TIMING

Ensure idle speed and ignition timing are set to specification. For adjustment procedures, see ON-VEHICLE ADJUSTMENTS - 4-CYLINDER article.

SUMMARY
If no faults were found while performing BASIC DIAGNOSTIC PROCEDURES, proceed to appropriate SELF-DIAGNOSTICS article. If no hard diagnostic trouble codes are found in self-diagnostics, proceed to TROUBLE SHOOTING - NO CODES article for diagnosis by symptom (i.e., ROUGH IDLE, NO START, etc.) or intermittent diagnostic procedures.

2002 ENGINE PERFORMANCE Self-Diagnostics - Corolla

2002 ENGINE PERFORMANCE Self-Diagnostics - Corolla

INTRODUCTION
NOTE: Before performing testing procedures, check for any related Technical Service Bulletins (TSBs).

To properly diagnosis and repair this vehicle, follow TESTING PROCEDURE under SELFDIAGNOSTIC SYSTEM. If no Diagnostic Trouble Codes (DTC) are present and a no start condition exists, proceed to BASIC DIAGNOSTIC PROCEDURES - 4-CYLINDER article. If no DTCs are present and a driveability condition exists, proceed to TROUBLE SHOOTING - NO CODES article for diagnosis by symptom (i.e., ROUGH IDLE, ENGINE STALLS, etc.).

SELF-DIAGNOSTIC SYSTEM
SYSTEM OVERVIEW Engine Control Module (ECM) monitors engine operation and contains a self-diagnostic system which stores Diagnostic Trouble Codes (DTC) and complies to On-Board Diagnostics Generation II (OBD-II) standards. Self-diagnostic system is used to provide vehicle with an on-board diagnostic system which is capable of continuously monitoring efficiency of emission control system, and improving diagnosis and repair when system failures occur. Federal Test Procedure (FTP) sets maximum allowable emission standards. A Malfunction Indicator Light (MIL) must illuminate if a system or component either fails or deteriorates to a point where the vehicle emissions could increase to more than 1 1/2 times FTP standards. If malfunction does not reoccur in 3 consecutive trips, MIL goes off, but DTCs remain recorded in ECM memory. DTCs may only be retrieved using an On-Board Diagnostic-II (OBD-II) scan tool that complies with SAE standard J-1978 or Toyota hand-held tester connected to Data Link Connector (DLC) No. 3. Scan tool also provides freeze frame data and can be used to clear DTCs. TWO-TRIP DETECTION LOGIC NOTE: When road testing vehicle in CHECK mode (Toyota hand-held tester only), two-trip detection logic will not function. Also, MIL will illuminate first time a malfunction is detected.

When a malfunction initially occurs, Diagnostic Trouble Code (DTC) will be temporarily stored in ECM memory, but MIL on instrument panel will not illuminate. The second time malfunction is detected, MIL on instrument panel will illuminate, provided ignition is turned off and then back on after first malfunction was detected. This is referred to as "Two-Trip Detection Logic" and only applies to specific DTCs. DATA LINK CONNECTOR

2002 ENGINE PERFORMANCE Self-Diagnostics - Corolla

OBD-II regulations (SAE J-1962) standardizes Data Link Connector (DLC) configurations. DLC is located under left side of instrument panel, left of steering column. See Fig. 1 .

Fig. 1: Connecting Scan Tool To Data Link Connector No. 3 Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. FREEZE FRAME DATA OBD-II scan tool or Toyota hand-held tester can by used to check freeze frame data. ECM records engine operating condition when a misfire, fuel trim (mixture) malfunction or other malfunction (fuel system, calculated load, coolant temperature, fuel trim (mixture), engine speed, vehicle speed, etc.) exists. If more than one DTC is detected, only data from the first malfunction is recorded. Recorded data is useful for determining conditions during which the malfunction occurred. MALFUNCTION INDICATOR LIGHT INSPECTION NOTE: CHECK engine light, located on instrument cluster, is referred to as Malfunction Indicator Light (MIL). Inspect MIL to ensure it is operational and will come on if a Diagnostic Trouble Code (DTC) is set.

1. Turn ignition on with engine off. Malfunction Indicator Light (MIL) should come on and remain on.

2002 ENGINE PERFORMANCE Self-Diagnostics - Corolla

If MIL comes on, go to next step. If MIL does not come on, check bulb circuit on instrument cluster and wiring circuit between MIL and ECM. See WIRING DIAGRAMS article. See ENGINE CONTROL MODULE LOCATION . 2. Start engine and ensure MIL goes off. If MIL goes off, no malfunction is detected at this time. If MIL remains on or blinks with engine running, a malfunction is detected. Proceed to RETRIEVING DIAGNOSTIC TROUBLE CODES . TESTING PROCEDURE To ensure correct diagnosis and repair, testing should be done in the following sequence:

Record Customer Complaint Ensure all customer complaints or observations are recorded. Test drive vehicle with customer when necessary for malfunction verification.

Retrieve Diagnostic Trouble Codes Connect scan tool to Data Link Connector No. 3. See Fig. 1 . Retrieve DTCS and record any freeze frame data (if applicable). See RETRIEVING DIAGNOSTIC TROUBLE CODES .

Clear Trouble Codes Clear DTCs and freeze frame data. See CLEARING DIAGNOSTIC TROUBLE CODES .

Visual Inspection Inspect all connectors of suspect circuit or component. Ensure all connections are clean and tight.

Confirm Symptoms & Trouble Codes Perform road test. Determine if original symptoms are still present. Retrieve DTCs. See RETRIEVING DIAGNOSTIC TROUBLE CODES .

Diagnose & Repair Diagnostic Trouble Codes Perform appropriate diagnosis and repair procedures under DIAGNOSTIC TESTS as necessary. For DTC descriptions, see DIAGNOSTIC TROUBLE CODE DEFINITIONS table under DIAGNOSTIC TROUBLE CODE DEFINITIONS. If no DTCs are present, proceed to TROUBLE SHOOTING - NO CODES article for diagnosis by symptom (i.e., ROUGH IDLE, NO START, etc.).

Verification Procedure After repairs have been completed, clear all DTCs. See CLEARING DIAGNOSTIC TROUBLE CODES . Perform road test. Ensure no DTCs are present and all symptoms and/or complaints have been repaired.

RETRIEVING DIAGNOSTIC TROUBLE CODES

2002 ENGINE PERFORMANCE Self-Diagnostics - Corolla

NOTE:

Diagnostic Trouble Codes (DTC) may be retrieved using Toyota hand-held tester or On-Board Diagnostic (OBD-II) scan tool that complies with SAE standard J-1978. Toyota hand-held tester or OBD-II scan tool may be operated in NORMAL mode when retrieving DTCs. Only Toyota hand-held tester may be used in CHECK mode when retrieving DTCs.

NORMAL mode is used to retrieve DTCs from Engine Control Module (ECM). CHECK mode is used to check for DTCs when operating vehicle to simulate conditions during which DTC was set. CHECK mode contains a higher sensing ability to detect malfunctions. CHECK mode helps determine malfunctions caused by poor electrical connections, which are difficult to determine using NORMAL mode. NOTE: If using Toyota hand-held tester, when ignition switch is turned from ON to ACC or OFF position, or scan tool is switched from NORMAL mode to CHECK mode, all DTCs and freeze frame data will be erased. DO NOT switch modes until all DTCs and freeze frame data have been recorded.

NORMAL Mode Code Retrieval

1. Connect scan tool to Data Link Connector (DLC) No. 3. See Fig. 1 . Turn ignition on with engine off. Turn scan tool on. Using scan tool manufacturer's instructions, check for DTCs and freeze frame data. 2. If scan tool displays UNABLE TO CONNECT TO VEHICLE, check DLC No. 3. See DATA LINK CONNECTOR NO. 3 INSPECTION under SCAN TOOL PROBLEMS. If scan tool does not display UNABLE TO CONNECT TO VEHICLE, go to next step. 3. Record any DTCs and freeze frame data displayed for system diagnosis. If driveability problem exists and no DTCs are present, go to TROUBLE SHOOTING - NO CODES article for diagnosis by symptom. 4. If any DTCs are present, perform appropriate DTC test under DIAGNOSTIC TESTS. For DTC descriptions, see DIAGNOSTIC TROUBLE CODE DEFINITIONS table under DIAGNOSTIC TROUBLE CODE DEFINITIONS. For more information on freeze frame data, see FREEZE FRAME DATA . For information on two-trip detection logic DTCs, see TWO-TRIP DETECTION LOGIC . 5. After repairs have been completed, clear DTCs from ECM. See CLEARING DIAGNOSTIC TROUBLE CODES . Road test vehicle to ensure all symptoms and/or complaints have been repaired.
CHECK Mode Code Retrieval (Toyota Hand-Held Tester Only)

NOTE:

If ignition switch is turned from ON to ACC or OFF position during CHECK mode, all DTCs and freeze frame data will be erased. DO NOT switch modes until all DTCs and freeze frame data are recorded.

1. Ensure vehicle battery is fully charged. Apply parking brake. Shift transmission/transaxle into Neutral (M/T) or Park (A/T). Turn A/C and all accessories off. Ensure throttle valve is fully closed. Turn ignition off. Connect scan tool to Data Link Connector (DLC) No. 3. See Fig. 1 . Turn ignition on with engine off. Turn scan tool on. 2. Switch scan tool from NORMAL mode to CHECK mode. CHECK mode is operational if MIL on instrument cluster flashes. Start engine. If no DTCs are present, MIL will turn off. Try to simulate conditions of driveability complaint described by customer. 3. Record any DTCs and freeze frame data displayed for system diagnosis. If driveability problem exists

2002 ENGINE PERFORMANCE Self-Diagnostics - Corolla

and no DTCs are present, go to TROUBLE SHOOTING - NO CODES article for diagnosis by symptom. 4. If any DTCs are present, perform appropriate DTC test under DIAGNOSTIC TESTS . For DTC description, see DIAGNOSTIC TROUBLE CODE DEFINITIONS table under DIAGNOSTIC TROUBLE CODE DEFINITIONS. For more information on freeze frame data, see FREEZE FRAME DATA . For information on two-trip detection logic DTCs, see TWO-TRIP DETECTION LOGIC . 5. After repairs for DTC have been completed, DTC must be cleared from ECM memory. See CLEARING DIAGNOSTIC TROUBLE CODES . Road test vehicle to ensure all symptoms and/or complaints have been repaired. CLEARING DIAGNOSTIC TROUBLE CODES 1. After performing repairs, clear Engine Control Module (ECM) memory of all stored Diagnostic Trouble Codes (DTC) and freeze frame data. DTCs and freeze frame data may be cleared by using scan tool and scan tool manufacturer's instructions. NOTE: If using Toyota hand-held tester, DTCs and freeze frame data may be cleared by switching from CHECK mode to NORMAL mode, or from NORMAL mode to CHECK mode. Depending on vehicle configuration, EFI fuse may be referred to as FHTR fuse.

NOTE:

2. DTCs and freeze frame data may also be cleared by removing EFI fuse from fuse block located in engine compartment. DTCs and freeze frame data may also be cleared by disconnecting negative battery cable. However, other memory functions (clock, radio, alarm, seats, etc.) will be cleared and must be reset. ENGINE CONTROL MODULE LOCATION For Engine Control Module (ECM) location, refer to illustration. See Fig. 2 .

2002 ENGINE PERFORMANCE Self-Diagnostics - Corolla

Fig. 2: Locating Engine Control Module Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TEST DRIVE CONFIRMATION

2002 ENGINE PERFORMANCE Self-Diagnostics - Corolla

1. On certain Diagnostic Trouble Codes (DTC), once DTC has been cleared from ECM memory, a DTC test drive confirmation test can be performed to verify repairs are made and that DTC does not reset. Test drive confirmation test will duplicate conditions required to set specified DTCs. 2. Test drive confirmation test lists the procedure to be performed to check that DTC does not reset. Test drive confirmation tests apply only to specific DTCs. Test drive confirmation test will be included within proper DTC test under DIAGNOSTIC TESTS .

SCAN TOOL PROBLEMS

DATA LINK CONNECTOR NO. 3 INSPECTION 1. If scan tool displays UNABLE TO CONNECT TO VEHICLE when scan tool is connected, try scan tool on another vehicle. If scan tool operates on another vehicle, go to next step. If scan tool does not operate on another vehicle, problem is probably with scan tool. 2. Check DLC No. 3 for loose or damaged terminals. Ensure DLC No. 3 terminals are in correct position in connector. See WIRING DIAGRAMS article. Repair as necessary. If connector and terminals are okay, go to next step. 3. Check voltage and resistance between ground and specified terminal on DLC No. 3. See DLC NO. 3 VOLTAGE & RESISTANCE SPECIFICATIONS table. See Fig. 3 . If voltage and resistance readings are not as specified, check wiring circuit. See WIRING DIAGRAMS article. DLC NO. 3 VOLTAGE & RESISTANCE SPECIFICATIONS Terminal No. (Circuit) (1) Specification 4 (Chassis Ground) Less Than One Ohm 5 (Signal Ground) Less Than One Ohm 16 (Battery Voltage) 9-14 Volts (1) Terminal No. 7 provides a pulse generation during information transmission (BUS communication) from Engine Control Module (ECM).

2002 ENGINE PERFORMANCE Self-Diagnostics - Corolla

Fig. 3: Identifying Data Link Connector No. 3 Terminals Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

SUMMARY
If no Diagnostic Trouble Codes (DTC) are present and a no start condition exists, proceed to BASIC DIAGNOSTIC PROCEDURES - 4-CYLINDER article. If no DTCs are present and a driveability symptoms exist or intermittents exist, proceed to TROUBLE SHOOTING - NO CODES article for diagnosis by symptom (i.e., ROUGH IDLE, ENGINE STALLS, etc.) or intermittent procedures.

DIAGNOSTIC TROUBLE CODE DEFINITIONS

DIAGNOSTIC TROUBLE CODE DEFINITIONS DTC (1) P0100 (2) P0101 P0110 (2) P0115 (2) P0116 P0120 (2) P0121 P0125 Description Mass Airflow Meter Circuit Mass Airflow Meter Circuit Range/Performance Intake Air Temperature Sensor Circuit Engine Coolant Temperature Sensor Circuit Engine Coolant Temperature Sensor Circuit Range/Performance Throttle Position (TP) Sensor Circuit Throttle Position (TP) Sensor Circuit Range/Performance Insufficient Coolant Temperature For Closed Loop Fuel Control

2002 ENGINE PERFORMANCE Self-Diagnostics - Corolla

P0128 P0130 P0133 P0135 (2) P0136 P0141 (2) P0171 P0172 P0300 P0301 P0302 P0303 P0304 P0325 (2) P0335 P0340 P0420 P0440 P0441 P0442 P0446 P0450 P0451 P0500 P0505 P0750 (3) P0753 (3) P0755 (3) P0758 (3) P0770 (3) P0773 (3) P1300 (2) P1305 (2) P1310 (2) P1315 (2) P1335 (4) P1346 P1349 P1520 P1600 P1656

Thermostat Malfunction Heated Oxygen Sensor No. 1 Circuit Heated Oxygen Sensor No. 1 Circuit Slow Response Heated Oxygen Sensor No. 1 Heater Circuit Heated Oxygen Sensor No. 2 Circuit Heated Oxygen Sensor No. 2 Heater Circuit System Too Lean System Too Rich Random Misfire Detected Cylinder No. 1 Misfire Detected Cylinder No. 2 Misfire Detected Cylinder No. 3 Misfire Detected Cylinder No. 4 Misfire Detected Knock Sensor Circuit Crankshaft Position Sensor Circuit Camshaft Position Sensor Circuit Catalyst System Efficiency Below Threshold Evaporative Emission Control System Incorrect EVAP Purge Flow Evaporative Emission Control System Leak Detected EVAP Vent Control Circuit EVAP Pressure Sensor Circuit EVAP Pressure Sensor Range/Performance Vehicle Speed Sensor Circuit Idle Air Control (IAC) System Circuit Shift Solenoid Valve No. 1 Malfunction Shift Solenoid Valve No. 1 Electrical Malfunction Shift Solenoid Valve No. 2 Malfunction Shift Solenoid Valve No. 2 Electrical Malfunction Lock-Up Solenoid Malfunction Lock-Up Solenoid Circuit Electrical Malfunction Ignitor No. 1 Circuit Ignitor No. 2 Circuit Ignitor No. 3 Circuit Ignitor No. 4 Circuit Crankshaft Position Sensor Circuit Variable Valve Timing Circuit Range/Performance Variable Valve Timing System Malfunction Stoplight Switch Signal Circuit (A/T Only) ECM BATT Circuit Oil Control Valve Malfunction

2002 ENGINE PERFORMANCE Self-Diagnostics - Corolla

P1780 Park/Neutral Position Switch Circuit (A/T Only) (1) Some DTCs are two-trip detection logic code(s). For more information, see TWO-TRIP DETECTION LOGIC under SELF-DIAGNOSTIC SYSTEM. (2) If this DTC is set, ECM will enter fail-safe mode.
(3) These DTCs only apply to models with electronically controlled transmissions. For testing

procedures, see appropriate ELECTRONIC CONTROLS article in AUTOMATIC TRANSMISSIONS. (4) MIL will not illuminate.

DIAGNOSTIC TESTS
NOTE: Before performing any diagnostic test, see SELF-DIAGNOSTIC SYSTEM for diagnostic system functions and system diagnostic procedures. Also check for any related Technical Service Bulletins (TSBs). For component location, see appropriate illustration in THEORY & OPERATION article. To identify ECM terminals referenced in testing, see illustration. See Fig. 5 or Fig. 4 .

NOTE:

Fig. 4: Identifying Engine Control Module Harness Connector Terminals (3-Speed A/T & M/T) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 5: Identifying Engine Control Module Harness Connector Terminals (4-Speed A/T) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. DTC P0100: MASS AIRFLOW METER CIRCUIT CAUTION: If ECM replacement is instructed in following testing, always ensure ECM connectors and ground circuits are okay. If either are suspect, repair and repeat testing to confirm ECM malfunction.

2002 ENGINE PERFORMANCE Self-Diagnostics - Corolla

NOTE:

For component location, see appropriate illustration in THEORY & OPERATION article.

Circuit Description

MAF meter uses a platinum hot wire maintained at a constant temperature. Airflow past sensor affects temperature and current flow through MAF meter. DTC is set when ECM detects an open or short in MAF meter circuit for more than 3 seconds with engine speed at 3000 RPM or less. ECM will operate in fail-safe mode if DTC P0100 is set. Possible causes are:

MAF meter circuit is open or shorted. Defective MAF meter. Defective ECM.

Diagnostic Aids

After confirming DTC P0100, use scan tool to access CURRENT DATA to confirm mass airflow meter air flow rate. If ratio is 0.0 gm/sec., VG circuit may be open or shorted, or power source circuit may be open. If ratio is 271.0 gm/sec. or more, EVG circuit may be open. Using scan tool, read FREEZE FRAME data. Freeze frame data records engine conditions when malfunction is detected.
Diagnosis & Repair

1. Connect scan tool to Data Link Connector (DLC) No. 3. See Fig. 1 . Start and warm engine to normal operating temperature. Using scan tool, monitor MAF flow rate. If scan tool reading is 0.0 gm/sec., go to next step. If scan tool reading is 271 gm/sec. or more, go to step 5 . 2. Turn ignition off. Disconnect MAF meter harness connector. Turn ignition on. Measure voltage between ground and terminal No. 1 (Black wire) at MAF meter harness connector. See Fig. 6 . If voltage is 9-14 volts, go to next step. If voltage is not 9-14 volts, repair open in Black wire between engine compartment junction box and MAF meter. See WIRING DIAGRAMS article. 3. Turn ignition off. Connect MAF meter harness connector. Access ECM below stereo, behind instrument panel, just in front of center console. See Fig. 2 . Ensure shift lever is in Neutral or Park. Ensure A/C switch is off. Start engine and let idle. Using DVOM, backprobe ECM harness connector. On models with 3-speed A/T and M/T, measure voltage between ground and terminal No. 2 (Green wire) at ECM harness connector E5. On models with 4-speed A/T transmission, measure voltage between ground and terminal No. 11 (Green wire) at ECM harness connector E8. See Fig. 5 . See Fig. 4 . If voltage is not .5-3.0 volts, go to next step. If voltage is .5-3.0 volts, replace ECM. 4. Check for open or short in Green wire between MAF meter and ECM. See WIRING DIAGRAMS article. If problem exists, repair wiring as necessary. If problem does not exist, replace MAF meter. 5. Turn ignition off. Access ECM below stereo, behind instrument panel, just in front of center console. See Fig. 2 . Using DVOM, backprobe ECM harness connector. On models with 3-speed A/T and M/T, measure resistance between ground and terminal No. 10 (Blue/White wire) at ECM harness connector E5. On models with 4-speed A/T transmission, measure resistance between ground and terminal No. 1 (Blue/White wire) at ECM harness connector E8. See Fig. 5 . See Fig. 4 . If resistance is one ohms or less, go to next step. If resistance is greater than one ohm, replace ECM. 6. Check for open in Blue/White wire between MAF meter and ECM. See WIRING DIAGRAMS article. If problem exists, repair wiring as necessary. If problem does not exist, replace MAF meter.

2002 ENGINE PERFORMANCE Self-Diagnostics - Corolla

Fig. 6: Identifying Mass Airflow Meter Harness Connector Terminals Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. DTC P0101: MASS AIRFLOW METER CIRCUIT RANGE/PERFORMANCE CAUTION: If ECM replacement is instructed in following testing, always ensure ECM connectors and ground circuits are okay. If either are suspect, repair and repeat testing to confirm ECM malfunction. NOTE: For component location, see appropriate illustration in THEORY & OPERATION article.

Circuit Description

Mass Airflow (MAF) meter uses a platinum hot wire maintained at a constant temperature. Airflow past sensor affects temperature and current flow through MAF meter. DTC is set when ECM detects either throttle valve is fully closed and MAF meter output is more than 2.2 volts for more than 10 seconds with engine speed of 900 RPM or less, or VTA circuit signal is .63 volt or more and MAF meter output is less than 1.06 volts for more than 10 seconds with engine speed of 1500 RPM or more. Possible cause is; defective MAF meter.
Diagnostic Aids

Using scan tool, read FREEZE FRAME data. Freeze frame data records engine conditions when malfunction is detected.
Diagnosis & Repair

If only DTC P0101 is displayed, replace MAF meter. If other DTCs are displayed, diagnose and repair those

2002 ENGINE PERFORMANCE Self-Diagnostics - Corolla

DTCs first and retest. DTC P0110: INTAKE AIR TEMPERATURE SENSOR CIRCUIT CAUTION: If ECM replacement is instructed in following testing, always ensure ECM connectors and ground circuits are okay. If either are suspect, repair and repeat testing to confirm ECM malfunction. NOTE: If DTCs P0110, P0115, P0120, P0440, P0441, P0446, P0450 and P0451 are output together, inspect ECM E2 circuit (sensor ground) between ECM and splice I8. Repair as necessary. See WIRING DIAGRAMS article. For component location, see appropriate illustration in THEORY & OPERATION article.

NOTE:

Circuit Description

Intake Air Temperature (IAT) sensor is a thermistor built into MAF meter and is used to monitor temperature of air flowing through MAF meter. DTC is set when ECM detects an open or short in IAT sensor circuit. ECM will operate in fail-safe mode if DTC P0110 is set. Possible causes are:

IAT sensor circuit is open or shorted. Defective IAT sensor (built into MAF meter). Defective ECM.

Diagnostic Aids

After confirming DTC P0110, use scan tool to access CURRENT DATA to confirm intake air temperature. If IAT sensor value displayed on scan tool is always -40F (-40C), IAT sensor circuit may be open. If IAT sensor value displayed on scan tool is always 284F (140C) or more, IAT sensor circuit may be shorted. Using scan tool, read FREEZE FRAME data. Freeze frame data records engine conditions when malfunction is detected.
Diagnosis & Repair

1. Connect scan tool to Data Link Connector (DLC) No. 3. See Fig. 1 . Turn ignition on. Using scan tool, monitor IAT sensor temperature. If temperature displayed on scan tool is same as intake air temperature, problem is intermittent. Check component and ECM connections. If temperature displayed on scan tool is 284F (140C) or more, go to step 4 . If temperature displayed on scan tool is -40F (-40C), go to next step. 2. Turn ignition off. Disconnect MAF meter harness connector. Connect a jumper wire between terminals No. 4 (Yellow/Black wire) and No. 5 (Brown wire) at MAF meter harness connector. See Fig. 6 . Turn ignition on. Using scan tool, monitor IAT sensor temperature. If temperature displayed on scan tool is 284F (140C) or more, replace MAF meter. If temperature displayed on scan tool is less than 284F (140C), go to next step. 3. Turn ignition off. Remove jumper wire. Access ECM below stereo, behind instrument panel, just in front of center console. See Fig. 2 . On models with 3-speed A/T and M/T, connect a jumper wire by backprobing between terminals No. 3 (Yellow/Black wire) and No. 9 (Brown wire) at ECM harness connector E5. See Fig. 4 . On models with 4-speed A/T transmission, connect a jumper wire by

2002 ENGINE PERFORMANCE Self-Diagnostics - Corolla

backprobing between terminals No. 22 (Yellow/Black wire) and No. 18 (Brown wire) at ECM harness connector E8. See Fig. 5 . On all models, temperature displayed on scan tool should be 284F (140C) or more. If temperature displayed on scan tool is as specified, repair open in wiring between MAF meter and ECM. See WIRING DIAGRAMS article. If temperature displayed on scan tool is not as specified, replace ECM. 4. Turn ignition off. Disconnect MAF meter harness connector. Turn ignition on. If temperature displayed on scan tool is -40F (-40C), replace MAF meter. If temperature displayed on scan tool is not -40F (-40C), go to next step. 5. Turn ignition off. Access ECM below stereo, behind instrument panel, just in front of center console. See Fig. 2 . On models with 3-speed A/T and M/T, disconnect ECM harness connector E5. See Fig. 4 . On models with 4-speed A/T transmission, disconnect ECM harness connector E8. See Fig. 5 . On all models, turn ignition on. If temperature displayed on scan tool is -40F (-40C), repair short in wiring between MAF meter and ECM. See WIRING DIAGRAMS article. If temperature displayed on scan tool is not -40F (-40C), replace ECM. DTC P0115: ENGINE COOLANT TEMPERATURE SENSOR CIRCUIT CAUTION: If ECM replacement is instructed in following testing, always ensure ECM connectors and ground circuits are okay. If either are suspect, repair and repeat testing to confirm ECM malfunction. NOTE: If DTCs P0110, P0115, P0120, P0440, P0441, P0446, P0450 and P0451 are output together, inspect ECM E2 circuit (sensor ground) between ECM and splice I8. Repair as necessary. See WIRING DIAGRAMS article. For component location, see appropriate illustration in THEORY & OPERATION article.

NOTE:

Circuit Description

Engine Coolant Temperature (ECT) sensor is a thermistor sensor which monitors engine coolant temperature. DTC is set when ECM detects an open or short in ECT sensor circuit. ECM will operate in failsafe mode if DTC P0115 is set. Possible causes are:

ECT sensor circuit is open or shorted. Defective ECT sensor. Defective ECM.

Diagnostic Aids

After confirming DTC P0115, use scan tool to access CURRENT DATA to confirm engine coolant temperature. If ECT sensor value displayed on scan tool is always -40F (-40C), ECT sensor circuit may be open. If ECT sensor value displayed on scan tool is always 284F (140C) or more, ECT sensor circuit may be shorted. Using scan tool, read FREEZE FRAME data. Freeze frame data records engine conditions when malfunction is detected.
Diagnosis & Repair

1. Connect scan tool to Data Link Connector (DLC) No. 3. See Fig. 1 . Turn ignition on. Using scan

2002 ENGINE PERFORMANCE Self-Diagnostics - Corolla

2.

3.

4.

5.

tool, monitor ECT sensor temperature. If temperature displayed on scan tool is same as actual coolant temperature, problem is intermittent. Check component and ECM connections. If temperature displayed on scan tool is 284F (140C) or more, go to step 4 . If temperature displayed on scan tool is -40F (-40C), go to next step. Turn ignition off. Disconnect ECT sensor harness connector. Connect a jumper wire between ECT sensor harness connector terminals. Turn ignition on. Using scan tool, monitor ECT sensor temperature. If temperature displayed on scan tool is 284F (140C) or more, replace ECT sensor. If temperature displayed on scan tool is less than 284F (140C), go to next step. Turn ignition off. Remove jumper wire. Access ECM below stereo, behind instrument panel, just in front of center console. See Fig. 2 . On models with 3-speed A/T and M/T, connect a jumper wire by backprobing between terminals No. 4 (White wire) and No. 9 (Brown wire) at ECM harness connector E5. See Fig. 4 . On models with 4-speed A/T transmission, connect a jumper wire by backprobing between terminals No. 14 (White wire) and No. 18 (Brown wire) at ECM harness connector E8. See Fig. 5 . On all models, temperature displayed on scan tool should be 284F (140C) or more. If temperature displayed on scan tool is as specified, repair open in wiring between ECT sensor and ECM. See WIRING DIAGRAMS article. If temperature displayed on scan tool is not as specified, replace ECM. Turn ignition off. Disconnect ECT sensor harness connector. Turn ignition on. If temperature displayed on scan tool is -40F (-40C), replace ECT sensor. If temperature displayed on scan tool is not -40F (-40C), go to next step. Turn ignition off. Access ECM below stereo, behind instrument panel, just in front of center console. See Fig. 2 . On models with 3-speed A/T and M/T, disconnect ECM harness connector E5. See Fig. 4 . On models with 4-speed A/T transmission, disconnect ECM harness connector E8. See Fig. 5 . On all models, turn ignition on. If temperature displayed on scan tool is -40F (-40C), repair short in wiring between ECT sensor and ECM. See WIRING DIAGRAMS article. If temperature displayed on scan tool is not -40F (-40C), replace ECM.

DTC P0116: ENGINE COOLANT TEMPERATURE SENSOR CIRCUIT RANGE/PERFORMANCE NOTE: If DTCs P0115 and P0116 are output together, an open may exist in ECT sensor circuit. Perform DTC P0115: ENGINE COOLANT TEMPERATURE SENSOR CIRCUIT test before performing DTC P0116 test. For component location, see appropriate illustration in THEORY & OPERATION article.

NOTE:

Circuit Description

Engine Coolant Temperature (ECT) sensor is a thermistor sensor which monitors engine coolant temperature. DTC is set when ECT sensor signal value is out of range during engine operation. Possible causes are:

Defective ECT sensor. Defective cooling system.

Diagnostic Aids

Using scan tool, read FREEZE FRAME data. Freeze frame data records engine conditions when

2002 ENGINE PERFORMANCE Self-Diagnostics - Corolla

malfunction is detected.
Diagnosis & Repair

1. If any other DTCs are displayed, diagnose and repair those DTCs first and retest. If only DTC P0116 is displayed, go to next step. 2. Remove and inspect cooling system thermostat. If problem exists, replace thermostat as necessary and retest system. If problem does not exist, replace ECT sensor. DTC P0120: THROTTLE POSITION SENSOR CIRCUIT CAUTION: If ECM replacement is instructed in following testing, always ensure ECM connectors and ground circuits are okay. If either are suspect, repair and repeat testing to confirm ECM malfunction. NOTE: If DTCs P0110, P0115, P0120, P0440, P0441, P0446, P0450 and P0451 are output together, inspect ECM E2 circuit (sensor ground) between ECM and splice I8. Repair as necessary. See WIRING DIAGRAMS article. For component location, see appropriate illustration in THEORY & OPERATION article.

NOTE:

Circuit Description

Throttle Position (TP) sensor is a variable resistor which monitors throttle opening. ECM determines vehicle driving condition and adjusts air/fuel mixture accordingly. DTC is set when ECM consistently detects less than .1 volt or more than 4.9 volts on VTA circuit. ECM will operate in fail-safe mode if DTC P0120 is set. Possible causes are:

TP sensor circuit is open or shorted. Defective TP sensor. Defective ECM.

Diagnostic Aids

After confirming DTC P0120, use scan tool to access CURRENT DATA to confirm throttle valve opening percentage with throttle open and closed. If percentage displayed on scan tool is always zero percent, VC circuit may be open, or VTA circuit may be open or shorted. If percentage displayed on scan tool is always 100 percent, E2 circuit may be open. Using scan tool, read FREEZE FRAME data. Freeze frame data records engine conditions when malfunction is detected.
Diagnosis & Repair

1. Connect scan tool to Data Link Connector (DLC) No. 3. See Fig. 1 . Turn ignition on. Using scan tool, monitor throttle valve opening percentage. Opening percentage should be approximately 10 percent with fully closed throttle, and should be approximately 80 percent with throttle fully open. If percentages are as specified, problem is intermittent. Check component and ECM connections. If percentages are not as specified, go to next step. 2. Turn ignition off. Disconnect TP sensor harness connector. Turn ignition on. Using DVOM, measure

2002 ENGINE PERFORMANCE Self-Diagnostics - Corolla

voltage between ground and terminal No. 1 (Yellow wire) at TP sensor harness connector. If voltage is 4.5-5.5 volts, go to next step. If voltage is not 4.5-5.5 volts, go to step 5 . 3. Check TP sensor. See ENGINE SENSORS & SWITCHES in SYSTEM & COMPONENT TESTING - 4-CYLINDER article. If problem exists, replace TP sensor. If problem does not exist, go to next step. 4. Turn ignition off. Connect TP sensor harness connector. Access ECM below stereo, behind instrument panel, just in front of center console. See Fig. 2 . Turn ignition on. Using DVOM, backprobe ECM harness connector. On models with 3-speed A/T and M/T, measure voltage between terminals No. 9 (Brown wire) and No. 11 (Light Green wire) at ECM harness connector E5. See Fig. 4 . On models with 4-speed A/T transmission, measure voltage between terminals No. 18 (Brown wire) and No. 23 (Light Green wire) at ECM harness connector E8. See Fig. 5 . On all models, voltage should be .3-1.0 volt with throttle fully closed and 3.2-4.9 volts with throttle fully open. If voltage is as specified, replace ECM. If voltage is not as specified, repair open or short in wiring between TP sensor and ECM. See WIRING DIAGRAMS article. 5. Access ECM below stereo, behind instrument panel, just in front of center console. See Fig. 2 . Turn ignition on. Using DVOM, backprobe ECM harness connector. On models with 3-speed A/T and M/T, measure voltage between terminals No. 1 (Yellow wire) and No. 9 (Brown wire) at ECM harness connector E5. See Fig. 4 . On models with 4-speed A/T transmission, measure voltage between terminals No. 2 (Yellow wire) and No. 18 (Brown wire) at ECM harness connector E8. See Fig. 5 . On all models, voltage should be 4.5-5.5 volts. If voltage is as specified, repair open in Yellow wire between TP sensor and ECM. If voltage is not as specified, replace ECM. DTC P0121: THROTTLE POSITION SENSOR CIRCUIT RANGE/PERFORMANCE
Circuit Description

Throttle Position (TP) sensor is a variable resistor which monitors throttle opening. ECM determines vehicle driving condition and adjusts air/fuel mixture accordingly. DTC is set after vehicle speed has exceeded 19 MPH once and TP sensor output voltage is out of range while vehicle speed is 0-19 MPH. Possible cause is; defective Throttle Position (TP) sensor.
Diagnostic Aids

After confirming DTC P0121, use scan tool to access CURRENT DATA to confirm throttle valve opening percentage with throttle open and closed. If percentage displayed on scan tool is always zero percent, VC circuit may be open or VTA circuit may be shorted. If percentage displayed on scan tool is always 100 percent, check for open in E2 circuit. Using scan tool, read FREEZE FRAME data. Freeze frame data records engine conditions when malfunction is detected.
Diagnosis & Repair

If only DTC P0121 is displayed, replace TP sensor. If any other DTCs are displayed, diagnose and repair those DTCs first and retest. DTC P0125: INSUFFICIENT COOLANT TEMPERATURE FOR CLOSED LOOP FUEL CONTROL CAUTION: If ECM replacement is instructed in following testing, always ensure ECM connectors and ground circuits are okay. If either are suspect, repair and repeat testing to confirm ECM malfunction.

2002 ENGINE PERFORMANCE Self-Diagnostics - Corolla

NOTE:

Heated oxygen sensor No. 1 refers to oxygen sensor closest to engine block. Heated oxygen sensor No. 2 refers to oxygen sensor farthest from engine block. For component location, see appropriate illustration in THEORY & OPERATION article. This DTC may be caused by the vehicle running out of fuel.

NOTE:

NOTE:

Circuit Description

Heated oxygen sensor monitors exhaust gas oxygen content and delivers an input signal to ECM. ECM uses input signal to determine fuel injection system operation. Heated oxygen sensor includes a heater. DTC is set when heated oxygen sensor No. 1 does not output a rich condition once engine is at normal operating temperature, engine speed is more than 1400 RPM and vehicle speed is 25-62 MPH for at least 2 minutes. Possible causes are:

Fuel system malfunction. Defective fuel injector. Ignition system malfunction. Exhaust system leak. Heated oxygen sensor No. 1 circuit is open or shorted. Defective heated oxygen sensor No. 1. Vehicle run out of fuel. Defective ECM.

Diagnostic Aids

After confirming DTC P0125, use scan tool to access CURRENT DATA to confirm voltage output of heated oxygen sensor No. 1. If voltage displayed on scan tool is always less than .1 volt, heated oxygen sensor No. 1 circuit may be open or shorted. Using scan tool, read FREEZE FRAME data. Freeze frame data records engine conditions when malfunction is detected.
Diagnosis & Repair

1. Connect scan tool to Data Link Connector (DLC) No. 3. See Fig. 1 . Start and warm engine to normal operating temperature. Using scan tool, monitor heated oxygen sensor No. 1. Snap accelerate engine to about 4000 RPM 3 times. Heated oxygen sensor No. 1 should indicate a rich signal (.45 volt or more) at least once. If a rich signal is indicated for heated oxygen sensor No. 1 at least once, replace ECM. If heated oxygen sensor No. 1 does not display a rich signal at least once, go to next step. 2. Check for open or short in wiring between heated oxygen sensor No. 1 and ECM. See WIRING DIAGRAMS article. If problem does not exists, go to next step. If problem exists, repair wiring as necessary. 3. Using scan tool, check if a misfire has occurred by monitoring DTCs and DATA LIST. If a misfire has occurred, perform DTC P0300: RANDOM MISFIRE DETECTED . If misfire has not occurred, go to next step. 4. Check exhaust system for leaks. If problem exists, repair as necessary. If problem does not exist,

2002 ENGINE PERFORMANCE Self-Diagnostics - Corolla

replace defective heated oxygen sensor No. 1. DTC P0128: THERMOSTAT MALFUNCTION CAUTION: If ECM replacement is instructed in following testing, always ensure ECM connectors and ground circuits are okay. If either are suspect, repair and repeat testing to confirm ECM malfunction.
Circuit Description

DTC is set when ECM detects coolant temperature is less than 167F (75C) when engine should be at normal operating temperature. Possible causes are:

Defective thermostat. Defective cooling system. Defective engine coolant temperature sensor. Defective ECM.

Diagnostic Aids

Using scan tool, read FREEZE FRAME data. Freeze frame data records engine conditions when malfunction is detected.
Diagnosis & Repair

1. Remove and inspect cooling system thermostat. If problem exists, replace thermostat as necessary and retest. If problem does not exist, go to next step. 2. If any other DTCs are displayed, diagnose and repair those DTCs first and retest. If only DTC P0128 is displayed, replace ECM. DTC P0130: HEATED OXYGEN SENSOR NO. 1 CIRCUIT CAUTION: If ECM replacement is instructed in following testing, always ensure ECM connectors and ground circuits are okay. If either are suspect, repair and repeat testing to confirm ECM malfunction. NOTE: Heated oxygen sensor No. 1 refers to oxygen sensor closest to engine block. Heated oxygen sensor No. 2 refers to oxygen sensor farthest from engine block.

Circuit Description

Heated oxygen sensor monitors exhaust gas oxygen content and delivers an input signal to ECM. ECM uses input signal to determine fuel injection system operation. Heated oxygen sensor includes a heater. DTC is set when heated oxygen sensor No. 1 voltage remains at .4 volt or more, or .55 volt or less during idle, once engine is at normal operating temperature. Possible causes are:

Defective heated oxygen sensor No. 1. Fuel trim malfunction.

2002 ENGINE PERFORMANCE Self-Diagnostics - Corolla

Diagnostic Aids

Using scan tool, read FREEZE FRAME data. Freeze frame data records engine conditions when malfunction is detected.
Test Drive Confirmation

1. If using OBD-II scan tool, go to step 3 . If using Toyota hand-held tester, connect hand-held tester to Data Link Connector (DLC) No. 3. See Fig. 1 . Switch hand-held tester to CHECK mode and go to next step. 2. Start and warm engine to normal operating temperature with all accessories off. Drive vehicle at 3140 MPH for 1-3 minutes. Stop vehicle and allow to idle for one minute. Repeat driving and idle part of test 3 times. If malfunction exists, MIL will illuminate. 3. Start and warm engine to normal operating temperature. Drive vehicle at 31-40 MPH for 1-3 minutes. Stop vehicle and allow to idle for one minute. Repeat driving and idle part of test 3 times. Go to next step. 4. Turn ignition off. Repeat step 3 . If malfunction exists, MIL will illuminate.
Diagnosis & Repair

1. Check for open or short circuit in wiring harness between ECM and heated oxygen sensor. See WIRING DIAGRAMS article. If problem exists, repair wiring as necessary. If problem does not exist, go to next step. 2. Connect scan tool to Data Link Connector (DLC) No. 3. See Fig. 1 . Start engine and warm to normal operating temperature. Monitor oxygen sensor output voltage and short-term fuel trim. If scan tool indicates a lean condition (.55 volt or less, +20 trim) or rich condition (.35 volt or more, -20 trim), check fuel trim system. See DTC P0171 OR P0172: SYSTEM TOO LEAN/RICH . If scan tool does not indicate a lean condition (.55 volt or less, +20 trim) or rich condition (.35 volt or more, -20 trim), go to next step. 3. Start engine and increase engine speed to 2500 RPM for approximately 90 seconds. Let engine idle. Using scan tool, monitor heated oxygen senor No. 1 output voltage. Voltage should alternate repeatedly between less than .4 volt and more than .55 volt. If voltage is as specified, perform TEST DRIVE CONFIRMATION . If voltage is not as specified, replace heated oxygen sensor. DTC P0133: HEATED OXYGEN SENSOR NO. 1 CIRCUIT SLOW RESPONSE NOTE: Heated oxygen sensor No. 1 refers to sensor closest to engine block. Heated oxygen sensor No. 2 refers to sensor farthest from engine block.

Circuit Description

Heated oxygen sensor monitors exhaust gas oxygen content and delivers an input signal to ECM. ECM uses input signal to determine fuel injection system operation. Heated oxygen sensor includes a heater. DTC is set when ECM detects a response time of one second or more from heated oxygen sensor to change from rich to lean, or lean to rich when engine is warm and idling. Possible causes are:

Defective heated oxygen sensor No. 1. Fuel trim malfunction.

2002 ENGINE PERFORMANCE Self-Diagnostics - Corolla

Diagnostic Aids

Using scan tool, read FREEZE FRAME data. Freeze frame data records engine conditions when malfunction is detected.
Diagnosis & Repair

If any other DTCs are displayed, diagnose and repair those DTCs first and retest system. If only DTC P0133 is displayed, replace heated oxygen sensor No. 1. DTC P0135: HEATED OXYGEN SENSOR NO. 1 HEATER CIRCUIT CAUTION: If ECM replacement is instructed in following testing, always ensure ECM connectors and ground circuits are okay. If either are suspect, repair and repeat testing to confirm ECM malfunction. NOTE: Heated oxygen sensor No. 1 refers to oxygen sensor closest to engine block. Heated oxygen sensor No. 2 refers to oxygen sensor farthest from engine block. For component location, see appropriate illustration in THEORY & OPERATION article.

NOTE:

Circuit Description

Heated oxygen sensor monitors exhaust gas oxygen content and delivers an input signal to ECM. ECM uses input signal to determine fuel injection system operation. Heated oxygen sensor includes a heater. DTC is set when heated oxygen sensor heater current draw exceeds 2 amps, or heated oxygen sensor heater current draw is .2 amp or less when heater operates. ECM will operate in fail-safe mode if DTC P0135 is set. Possible causes are:

Heated oxygen sensor No. 1 heater circuit is open or shorted. Defective heated oxygen sensor No. 1 heater. Defective ECM.

Diagnostic Aids

Using scan tool, read FREEZE FRAME data. Freeze frame data records engine conditions when malfunction is detected.
Diagnosis & Repair

1. Access ECM below stereo, behind instrument panel, just in front of center console. See Fig. 2 . Turn ignition on. Using DVOM, backprobe ECM harness connector. On models with 3-speed A/T and M/T, measure voltage between ground and terminal No. 7 (Pink wire) at ECM harness connector E5. See Fig. 4 . On models with 4-speed A/T transmission, measure voltage between ground and terminal No. 3 (Pink wire) at ECM harness connector E8. See Fig. 5 . On all models, voltage should be 9-14 volts. If voltage is as specified, replace ECM. If voltage is not as specified, go to next step. 2. Disconnect heated oxygen sensor No. 1 harness connector. Measure resistance between terminals B+

2002 ENGINE PERFORMANCE Self-Diagnostics - Corolla

(Black wire) and HT (Pink wire) at heated oxygen sensor No. 1 (component side). See Fig. 7 . Resistance should be 11-16 ohms at 68F (20C). If resistance is not as specified, replace heated oxygen sensor No. 1. If resistance is as specified, go to next step. 3. Repair wiring between ECM and heated oxygen sensor No. 1, or between heated oxygen sensor No. 1 and engine room junction box. See WIRING DIAGRAMS article.

Fig. 7: Testing Heated Oxygen Sensor No. 1 Heater Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. DTC P0136: HEATED OXYGEN SENSOR NO. 2 CIRCUIT NOTE: Heated oxygen sensor No. 1 refers to oxygen sensor closest to engine block. Heated oxygen sensor No. 2 refers to oxygen sensor farthest from engine block. For component location, see appropriate illustration in THEORY & OPERATION article.

NOTE:

Circuit Description

Heated oxygen sensor monitors exhaust gas oxygen content and delivers an input signal to ECM. ECM uses input signal to determine fuel injection system operation. Heated oxygen sensor includes a heater. DTC is set when heated oxygen sensor No. 2 voltage remains at .4 volt or more, or .5 volt or less during vehicle operation (25 MPH or more), once engine is at normal operating temperature. Possible cause is; defective heated oxygen sensor No. 2.

2002 ENGINE PERFORMANCE Self-Diagnostics - Corolla

Diagnostic Aids

Using scan tool, read FREEZE FRAME data. Freeze frame data records engine conditions when malfunction is detected.
Diagnosis & Repair

1. If any other DTCs are displayed, diagnose and repair those DTCs first. If only DTC P0136 is displayed, go to next step. 2. Check for open or short in wiring between ECM and heated oxygen sensor No. 2. See WIRING DIAGRAMS article. If problem exists, repair wiring as necessary. If problem does not exist, go to next step. 3. Connect scan tool to Data Link Connector (DLC) No. 3. See Fig. 1 . Start and warm engine to normal operating temperature. Monitor heated oxygen sensor No. 2 output voltage. Snap accelerate engine to about 4000 RPM 3 times. Voltage should fluctuate from less than .4 volt to .5 volt or more. If voltage is as specified, problem is intermittent. Check component and ECM connections. If voltage is not as specified, replace heated oxygen sensor No. 2. DTC P0141: HEATED OXYGEN SENSOR NO. 2 HEATER CIRCUIT CAUTION: If ECM replacement is instructed in following testing, always ensure ECM connectors and ground circuits are okay. If either are suspect, repair and repeat testing to confirm ECM malfunction. NOTE: Heated oxygen sensor No. 1 refers to oxygen sensor closest to engine block. Heated oxygen sensor No. 2 refers to oxygen sensor farthest from engine block. For component location, see appropriate illustration in THEORY & OPERATION article.

NOTE:

Circuit Description

Heated oxygen sensor monitors exhaust gas oxygen content and delivers an input signal to ECM. ECM uses input signal to determine fuel injection system operation. Heated oxygen sensor includes a heater. DTC is set when heated oxygen sensor No. 2 heater current draw exceeds 2 amps, or heated oxygen sensor heater current draw is .2 amp or less when heater operates. ECM will operate in fail-safe mode if DTC P0141 is set. Possible causes are:

Heated oxygen sensor No. 2 heater circuit is open or shorted. Defective heated oxygen sensor No. 2 heater. Defective ECM.

Diagnostic Aids

Using scan tool, read FREEZE FRAME data. Freeze frame data records engine conditions when malfunction is detected.
Diagnosis & Repair

2002 ENGINE PERFORMANCE Self-Diagnostics - Corolla

1. Access ECM below stereo, behind instrument panel, just in front of center console. See Fig. 2 . Turn ignition on. Using DVOM, backprobe ECM harness connector. On models with 3-speed A/T and M/T, measure voltage between ground and terminal No. 15 (Pink wire) at ECM harness connector E5. See Fig. 4 . On models with 4-speed A/T transmission, measure voltage between ground and terminal No. 6 (Pink wire) at ECM harness connector E8. See Fig. 5 . On all models, voltage should be 9-14 volts. If voltage is as specified, replace ECM. If voltage is not as specified, go to next step. 2. Disconnect heated oxygen sensor No. 2 harness connector. It might be necessary to remove passenger's seat to access harness connector. Measure resistance between terminals B+ (Black wire) and HT (Pink wire) at heated oxygen sensor No. 2 (component side). See Fig. 8 . Resistance should be 11-16 ohms at 68F (20C). If resistance is not as specified, replace heated oxygen sensor No. 2. If resistance is as specified, go to next step. 3. Repair wiring between ECM and heated oxygen sensor No. 2, or between heated oxygen sensor No. 2 and engine room junction box. See WIRING DIAGRAMS article.

Fig. 8: Testing Heated Oxygen Sensor No. 2 Heater Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. DTC P0171 OR DTC P0172: SYSTEM TOO LEAN/RICH CAUTION: If ECM replacement is instructed in following testing, always ensure ECM connectors and ground circuits are okay. If either are suspect, repair and repeat testing to confirm ECM malfunction. NOTE: Heated oxygen sensor No. 1 refers to oxygen sensor closest to engine block.

2002 ENGINE PERFORMANCE Self-Diagnostics - Corolla

Heated oxygen sensor No. 2 refers to oxygen sensor farthest from engine block. NOTE: For component location, see appropriate illustration in THEORY & OPERATION article.

Circuit Description

Fuel trim refers to feedback compensation value compared against basic injection time. Fuel trim includes short-term and long-term fuel trim. DTC P0171 is set when fuel trim is driven rich beyond a certain value. Possible causes are:

Exhaust system leak. Improper fuel pressure. Fuel injector restricted. Defective heated oxygen sensor No. 1. Defective Mass Airflow (MAF) meter. Defective Engine Coolant Temperature (ECT) sensor. Vehicle is ran out of fuel.

DTC P0172 is set when fuel trim is driven lean beyond a certain value. Possible causes are:

Exhaust system leak. Improper fuel pressure. Fuel injector blocked or leaking. Defective heated oxygen sensor No. 1. Defective Mass Airflow (MAF) meter. Defective Engine Coolant Temperature (ECT) sensor. Vehicle is ran out of fuel.

Diagnostic Aids

Using scan tool, read FREEZE FRAME data. Freeze frame data records engine conditions when malfunction is detected.
Diagnosis & Repair

1. Ask customer if vehicle ran out of fuel. If vehicle ran out of fuel, clear DTCs and retest. If vehicle did not run out of fuel, go to next step. 2. Ensure oil dipstick, oil filler cap, PCV system and all other air induction system components are intact and operating properly. If problem exists, repair as necessary. If problem does not exist, go to next step. 3. Connect scan tool to Data Link Connector (DLC) No. 3. See Fig. 1 . Start engine and warm to normal operating temperature. Monitor oxygen sensor output voltage and short-term fuel trim. If scan tool indicates a lean condition (.55 volt or less, +20 trim) or rich condition (.35 volt or more, -20 trim), go to next step. If scan tool does not indicate a lean condition (.55 volt or less, +20 trim) or rich condition

2002 ENGINE PERFORMANCE Self-Diagnostics - Corolla

4.

5.

6.

7.

8.

(.35 volt or more, -20 trim), Check heated oxygen sensor No. 1 circuit. See DTC P0130: HEATED OXYGEN SENSOR NO. 1 CIRCUIT . Check fuel pressure. See FUEL SYSTEMS in BASIC DIAGNOSTIC PROCEDURES - 4CYLINDER article. Fuel pressure should be 44-50 psi (3.1-3.5 kg/cm2 ) at idle, and should be 21 psi (1.5 kg/cm2 ) or more for 5 minutes after engine has stopped. If fuel pressure is not as specified, repair as necessary. If fuel pressure is as specified, go to next step. Check fuel injectors. See FUEL SYSTEMS in SYSTEM & COMPONENT TESTING - 4CYLINDER article. Fuel injector volume should be 3.7-4.5 cu. in. (60-73 cc) every 15 seconds and difference in volume between each injector should be less than .8 cu. in. (13 cc). Injectors should not leak more than one drop every 12 minutes. If problem exists, repair as necessary. If problem does not exist, go to next step. Check Mass Airflow (MAF) meter and Engine Coolant Temperature (ECT) sensor. See THEORY & OPERATION in SYSTEM & COMPONENT TESTING - 4-CYLINDER article. If problem exists, replace appropriate component. If problem does not exist, go to next step. Check spark and ignition system. See IGNITION SYSTEMS in BASIC DIAGNOSTIC PROCEDURES - 4-CYLINDER article. If problem exists, repair as necessary. If problem does not exist, go to next step. Check exhaust system for leaks. If problem exists, repair as necessary. If problem does not exist, replace ECM.

DTC P0300: RANDOM MISFIRE DETECTED NOTE: For component location, see appropriate illustration in THEORY & OPERATION article.

Circuit Description

ECM uses signals provided by crankshaft and camshaft position sensors. If engine speed rate has changed enough to equal a preset number, a misfire is detected and MIL is illuminated. If misfire rate is great enough, and driving conditions will cause catalytic converter damage or overheating, MIL blinks when a misfire is occurring. DTC is set when misfiring of random cylinders is detected during any particular 200 or 1000 revolutions. Possible causes are:

Ignition system malfunction. Defective fuel injector(s). Improper fuel pressure. Improper engine compression. Improper valve clearance. Improper valve timing. Defective Mass Airflow (MAF) meter. Defective Engine Coolant Temperature (ECT) sensor. Open or short in wiring. Poor contact at ECM or component. Defective ECM.

Diagnostic Aids

2002 ENGINE PERFORMANCE Self-Diagnostics - Corolla

When 2 or more DTCs for misfiring cylinder are recorded repeatedly but no random misfire DTC is recorded, it indicates misfires were detected and recorded at different times. If misfire cannot be reproduced, reason may be because of driving with lack of fuel, improper fuel, fouled spark plug, etc. Using scan tool, read FREEZE FRAME data. Freeze frame data records engine conditions when malfunction is detected.
Test Drive Confirmation

1. Connect scan tool to Data Link Connector (DLC) No. 3. See Fig. 1 . Record any DTCs and FREEZE FRAME data. Switch scan tool to CHECK mode (Toyota hand-held tester only). Drive vehicle several times with engine speed, load and its surrounding range shown with ENGINE SPD, CALC LOAD in FREEZE FRAME data or MISFIRE RPM and MISFIRE LOAD in scan tool data list. 2. Drive vehicle at specified engine speeds. See DRIVING PATTERN table. Turn ignition off after symptom is simulated the first time, then repeat test drive (OBD-II scan tool only). If a misfire is detected, a DTC will set and misfire will be indicated in FREEZE FRAME data. Turn ignition off and wait a minimum of 5 seconds. DRIVING PATTERN RPM Idling 1000 2000 3000 (1) Minimum specification is given.
Diagnosis & Repair
(1) Minutes

3 1/2 3 1 1/2 1

1. Check vacuum hoses for leaks, blockage and proper routing. See appropriate illustration in VACUUM DIAGRAMS article. Also, check wiring and connectors for damage or poor connections. If problem exists, repair as necessary and perform TEST DRIVE CONFIRMATION . If problem does not exist, go to next step. 2. Check spark and ignition system. See IGNITION SYSTEMS in BASIC DIAGNOSTIC PROCEDURES - 4-CYLINDER article. If problem exists, repair as necessary. If problem does not exist, go to next step. 3. Access ECM below stereo, behind instrument panel, just in front of center console. See Fig. 2 . Turn ignition on. Using DVOM, backprobe ECM connector and measure voltage between ground and fuel injector terminals at appropriate ECM harness connector. See IDENTIFYING FUEL INJECTOR TERMINALS table. See Fig. 5 or Fig. 4 . If voltage is 9-14 volts at each terminal, go to step 6 . If voltage is not 9-14 volts at each terminal, go to next step. IDENTIFYING FUEL INJECTOR TERMINALS Fuel Injector No. Terminal No. Wire Color With 4A/T Transmission (1) 1 1 2 2 3 3 Yellow Black/Red White

2002 ENGINE PERFORMANCE Self-Diagnostics - Corolla

Black

Without 4A/T Transmission (2) 1 12 Yellow 2 11 Black/Red 3 25 White 4 24 Black (1) Terminals are located at ECM harness connector E7. See Fig. 5 . (2) Terminals are located at ECM harness connector E4. See Fig. 4 . 4. Disconnect fuel injector harness connector at misfiring cylinder. Measure resistance between fuel injector terminals (component side). Resistance should be 13.4-14.2 ohms at 68F (20C). If resistance is as specified, go to next step. If resistance is not as specified, replace fuel injector. 5. Check for open or short in wiring between ECM and fuel injector. See WIRING DIAGRAMS article. If problem exists, repair as necessary. If problem does not exist, repair open or short in injector power source circuit. See WIRING DIAGRAMS article. 6. Check fuel pressure. See FUEL SYSTEMS in BASIC DIAGNOSTIC PROCEDURES - 4CYLINDER article. Fuel pressure should be 44-50 psi (3.1-3.5 kg/cm2 ) at idle, and should be 21 psi (1.5 kg/cm2 ) or more for 5 minutes after engine has stopped. If fuel pressure is not as specified, repair as necessary. If fuel pressure is as specified, go to next step. 7. Check fuel injectors. See THEORY & OPERATION in SYSTEM & COMPONENT TESTING - 4CYLINDER article. Fuel injector volume should be 3.7-4.5 cu. in. (60-73 cc) every 15 seconds and difference in volume between each injector should be less than .8 cu. in. (13 cc). Injectors should not leak more than one drop every 12 minutes. If problem exists, repair as necessary. If problem does not exist, go to next step. 8. Check Mass Airflow (MAF) meter and Engine Coolant Temperature (ECT) sensor. See THEORY & OPERATION in SYSTEM & COMPONENT TESTING - 4-CYLINDER article. If problem exists, replace appropriate component. If problem does not exist, go to next step. 9. Check engine compression. See BASIC DIAGNOSTIC PROCEDURES - 4-CYLINDER article. Check valve clearance. See ON-VEHICLE ADJUSTMENTS - 4-CYLINDER article. Check valve timing. See appropriate article in ENGINES. Repair as necessary. DTC P0301: CYLINDER NO. 1 MISFIRE DETECTED, DTC P0302: CYLINDER NO. 2 MISFIRE DETECTED, DTC P0303: CYLINDER NO. 3 MISFIRE DETECTED &/OR DTC P0304: CYLINDER NO. 4 MISFIRE DETECTED NOTE: When 2 or more DTCs for a misfiring cylinder are recorded repeatedly but DTC P0300 is not recorded, it indicates misfires were detected and stored into ECM memory at different times. For component location, see appropriate illustration in THEORY & OPERATION article.

NOTE:

Circuit Description

2002 ENGINE PERFORMANCE Self-Diagnostics - Corolla

ECM uses signals provided by crankshaft and camshaft position sensors. If engine speed rate has changed enough to equal a preset number, a misfire is detected and MIL is illuminated. If misfire rate is great enough, and driving conditions will cause catalytic converter damage or overheating, MIL blinks when a misfire is occurring. DTC is set during any particular 200 revolutions of engine during which misfiring is detected which can cause catalytic converter overheating and/or damage, or during any particular 1000 revolutions of engine during which misfiring is detected which can cause a deterioration in emission levels. Possible causes are:

Ignition system malfunction. Defective fuel injector(s). Improper fuel pressure. Improper engine compression. Improper valve clearance. Improper valve timing. Defective Mass Airflow (MAF) meter. Defective Engine Coolant Temperature (ECT) sensor. Open or short in wiring. Poor contact at ECM or component. Defective ECM.

Diagnostic Aids

When 2 or more DTCs for misfiring cylinder are recorded repeatedly but no random misfire DTC is recorded, it indicates misfires were detected and recorded at different times. If misfire cannot be reproduced, reason may be because of driving with lack of fuel, improper fuel, fouled spark plug, etc. Using scan tool, read FREEZE FRAME data. Freeze frame data records engine conditions when malfunction is detected.
Diagnosis & Repair

For diagnosis and repair procedure, see DTC P0300: RANDOM MISFIRE DETECTED . DTC P0325: KNOCK SENSOR CIRCUIT CAUTION: If ECM replacement is instructed in following testing, always ensure ECM connectors and ground circuits are okay. If either are suspect, repair and repeat testing to confirm ECM malfunction. NOTE: For component location, see appropriate illustration in THEORY & OPERATION article.

Circuit Description

Knock sensor generates voltage when engine block vibrates due to knocking. DTC is set when there is no knock sensor signal to ECM when engine speed is 1200 RPM or more. ECM will operate in fail-safe mode if DTC P0325 is set. Possible causes are:

Knock sensor circuit is open or shorted.

2002 ENGINE PERFORMANCE Self-Diagnostics - Corolla

Defective or loose knock sensor. Defective ECM.

Diagnostic Aids

Normal mode vibration frequency of knock sensor is 12.5 kHz. Using scan tool, read FREEZE FRAME data. Freeze frame data records engine conditions when malfunction is detected.
Diagnosis & Repair

1. Access ECM below stereo, behind instrument panel, just in front of center console. See Fig. 2 . On models with 3-speed A/T and M/T, disconnect ECM harness connector E4. See Fig. 4 . On models with 4-speed A/T transmission, disconnect ECM harness connector E7. See Fig. 5 . On all models use DVOM and backprobe ECM harness connector. On models with 3-speed A/T and M/T, measure resistance between ground and terminal No. 18 (Black wire) at ECM harness connector E4. On models with 4-speed A/T transmission, measure resistance between ground and terminal No. 27 (Black wire) at ECM harness connector E7. On all models, resistance should be one megohm or more. If resistance is as specified, go to step 3 . If resistance is not as specified, go to next step. 2. Disconnect knock sensor harness connector. Check continuity between knock sensor terminal and knock sensor housing. If continuity does not exist, go to next step. If continuity exists, replace knock sensor. 3. Check for open or short in wiring between knock sensor and ECM. See WIRING DIAGRAMS article. If problem exists, repair wiring as necessary. If problem does not exist, substitute knock sensor with known-good knock sensor. Clear and then retrieve DTCs. If DTC P0325 is still displayed, replace ECM. If DTC P0325 is no longer displayed, replace knock sensor. DTC P0335 OR DTC P1335: CRANKSHAFT POSITION SENSOR CIRCUIT CAUTION: If ECM replacement is instructed in following testing, always ensure ECM connectors and ground circuits are okay. If either are suspect, repair and repeat testing to confirm ECM malfunction. NOTE: For component location, see appropriate illustration in THEORY & OPERATION article.

Circuit Description

Crankshaft Position (CKP) sensor is a pick-up coil mounted next to crankshaft pulley. A 34-tooth signal plate is mounted to crankshaft. DTC P0335 is set if no cranking signal is received by ECM from sensor. DTC P1335 is set if no engine running signal is received by ECM from CKP sensor. Possible causes are:

CKP sensor circuit is open or shorted. Defective CKP sensor. Defective signal. Defective ECM.

Diagnostic Aids

Using scan tool, read FREEZE FRAME data. Freeze frame data records engine conditions when

2002 ENGINE PERFORMANCE Self-Diagnostics - Corolla

malfunction is detected.
Diagnosis & Repair

NOTE:

A sensor is considered to be cold when sensor coils are 14-122F (-10-50C). A sensor is considered to be hot when sensor coils are 122-212F (50-100C).

1. Disconnect CKP sensor harness connector. Measure resistance between CKP sensor terminals (component side). Resistance should be 1630-2740 ohms (cold sensor) or 2065-3225 ohms (hot sensor). If problem exists, replace CKP sensor. If problem does not exist, go to next step. 2. Check for open or short in wiring between ECM and CKP sensor. See WIRING DIAGRAMS article. If problem exists, repair wiring as necessary. If problem does not exist, go to next step. 3. Remove and inspect CKP sensor. Also, inspect crankshaft timing pulley teeth. If problem exists, replace CKP sensor and/or crankshaft timing pulley as necessary. If problem does not exist, replace ECM. DTC P0340: CAMSHAFT POSITION SENSOR CIRCUIT CAUTION: If ECM replacement is instructed in following testing, always ensure ECM connectors and ground circuits are okay. If either are suspect, repair and repeat testing to confirm ECM malfunction. NOTE: For component location, see appropriate illustration in THEORY & OPERATION article.

Circuit Description

Camshaft Position (CMP) sensor ("G" signal) consist of a signal plate and pick-up coil. "G" signal plate has one tooth on its outer circumference and is mounted on exhaust camshaft. DTC is set when no cranking or engine running signal is received by ECM from CMP sensor. Possible causes are:

CMP sensor circuit is open or shorted. Defective CMP sensor. Defective signal plate. Defective ECM.

Diagnostic Aids

Using scan tool, read FREEZE FRAME data. Freeze frame data records engine conditions when malfunction is detected.
Diagnosis & Repair

NOTE:

A sensor is considered to be cold when sensor coils are 14-122F (-10-50C). A sensor is considered to be hot when sensor coils are 122-212F (50-100C).

1. Disconnect CMP sensor harness connector. Measure resistance between CMP sensor terminals (component side). Resistance should be 835-1400 ohms (cold sensor) or 1060-1645 ohms (hot

2002 ENGINE PERFORMANCE Self-Diagnostics - Corolla

sensor). If resistance is not as specified, replace CMP sensor. If resistance is as specified, go to next step. 2. Check for open or short in wiring between ECM and CMP sensor. See WIRING DIAGRAMS article. If problem exists, repair wiring as necessary. If problem does not exist, go to next step. 3. Remove and inspect CMP sensor. Also, inspect camshaft signal plate. If problem exists, replace CMP sensor and/or camshaft signal plate as necessary. If problem does not exist, replace ECM. DTC P0420: CATALYST SYSTEM EFFICIENCY BELOW THRESHOLD NOTE: Heated oxygen sensor No. 1 refers to oxygen sensor closest to engine block. Heated oxygen sensor No. 2 refers to oxygen sensor farthest from engine block. For component location, see appropriate illustration in THEORY & OPERATION article.

NOTE:

Circuit Description

ECM compares waveform of heated oxygen sensor located in front of catalytic converter with waveform of heated oxygen sensor located after catalytic converter to determine if converter performance has deteriorated. If both waveforms change at similar rate, catalyst performance has deteriorated. DTC is set when both oxygen sensors have same amplitude after vehicle is driven for 5 minutes at 20-50 MPH. Possible causes are:

Defective catalytic converter. Heated oxygen sensor No. 2 circuit is open or shorted. Defective heated oxygen sensor No. 2.

Diagnostic Aids

Using scan tool, read FREEZE FRAME data. Freeze frame data records engine conditions when malfunction is detected.
Diagnosis & Repair

1. If any other DTCs are displayed, diagnose and repair those DTCs first. If only DTC P0420 is displayed, go to next step. 2. Check exhaust system for leaks. If problem exists, repair as necessary. If problem does not exist, go to next step. 3. Check heated oxygen sensor No. 1. See DTC P0130: HEATED OXYGEN SENSOR NO. 1 CIRCUIT . If problem exists, repair as necessary. If problem does not exist, go to next step. 4. Check heated oxygen sensor No. 2. See DTC P0136: HEATED OXYGEN SENSOR NO. 2 CIRCUIT test. If problem exists, repair as necessary. If problem does not exist, replace catalytic converter. DTC P0440: EVAPORATIVE EMISSION CONTROL SYSTEM OR DTC P0442: EVAPORATIVE EMISSION CONTROL SYSTEM LEAK DETECTED

2002 ENGINE PERFORMANCE Self-Diagnostics - Corolla

CAUTION: If ECM replacement is instructed in following testing, always ensure ECM connectors and ground circuits are okay. If either are suspect, repair and repeat testing to confirm ECM malfunction. NOTE: If DTCs P0110, P0115, P0120, P0440, P0441, P0446, P0450 and P0451 are output together, inspect ECM E2 circuit (sensor ground) between ECM and splice I8. Repair as necessary. See WIRING DIAGRAMS article. If DTC P0441, P0446, P0450 or P0451 is output after DTC P0440 or P0442, perform appropriate test first before performing DTC P0440 test. For component location, see appropriate illustration in THEORY & OPERATION article.

NOTE:

NOTE:

Circuit Description

Vapor pressure sensor, canister closed valve Vacuum Switching Valve (VSV) and pressure switching valve VSV are used to detect faults in EVAP system. DTC is set if EVAP system leak is detected or vapor pressure sensor malfunctions. Possible causes are:

Damaged, disconnected or blocked vacuum hose(s). Fuel tank cap is installed incorrectly. Defective fuel tank cap. Damaged fuel tank. Defective charcoal canister. Vapor pressure sensor circuit is open or shorted. Defective vapor pressure sensor. Defective fuel tank overfill valve. Defective ECM.

Diagnostic Aids

Ask customer if fuel tank cap has been left off or not completely tighten recently. This may cause DTC to be set. Using scan tool, read FREEZE FRAME data. Freeze frame data records engine conditions when malfunction is detected.
Diagnosis & Repair

1. Check for cracks and deformations in fuel tank, charcoal canister and fuel tank filler pipe. Check for disconnected hoses and tubes around fuel tank and charcoal canister. If problem exists, repair as necessary. If problem does not exist, go to next step. 2. Check fuel tank cap. If fuel tank cap is not an OEM cap, replace fuel tank cap with an OEM cap. If fuel tank cap is an OEM cap, go to next step. 3. Check if fuel tank cap is properly installed. If problem exists, install fuel tank cap properly. If fuel tank cap is properly installed, go to next step. 4. Check for damaged fuel tank cap and gasket. If problem exists, replace fuel tank cap with OEM cap. If problem does not exist, go to next step.

2002 ENGINE PERFORMANCE Self-Diagnostics - Corolla

5. Remove fuel tank cap. Visually inspect fuel tank filler neck for damage. If problem exists, replace fuel tank filler neck as necessary. If problem does not exist, go to next step. 6. Check vacuum hoses between vapor pressure sensor and fuel tank, and between charcoal canister and pressure switching valve VSV. Check hoses for correct installation, looseness and damage. If problem exists, repair vacuum hoses as necessary. If problem does not exist, go to next step. 7. Check hose and tube between fuel tank and charcoal canister for correct installation and damage. If problem exists, repair as necessary. If problem does not exist, go to next step. 8. Check charcoal canister for damage. If problem exists, repair or replace as necessary. If problem does not exist, go to next step. 9. Access ECM below stereo, behind instrument panel, just in front of center console. See Fig. 2 . Turn ignition on. Using DVOM, backprobe ECM harness connector. On models with 3-speed A/T and M/T, measure voltage between terminals No. 1 (Yellow wire) and No. 9 (Brown wire) at ECM harness connector E5. See Fig. 4 . On models with 4-speed A/T transmission, measure voltage between terminals No. 2 (Yellow wire) and No. 18 (Brown wire) at ECM harness connector E8. See Fig. 5 . On all models, voltage should be 4.5-5.5 volts. If voltage is not as specified, replace ECM. If voltage is as specified, go to next step. 10. Using DVOM, backprobe ECM harness connector. On models with 3-speed A/T and M/T, measure voltage between terminal No. 17 (Blue wire) at ECM harness connector E4 and terminal No. 9 (Brown wire) at ECM harness connector E5. On models with 4-speed A/T transmission, measure voltage between terminals No. 9 (Blue wire) and No. 18 (Brown wire) at ECM harness connector E5. On all models, disconnect vacuum hose from vapor pressure sensor. See Fig. 9 . Vapor pressure sensor is mounted on charcoal canister. Connect a vacuum pump to vapor pressure sensor. Voltage should be 2.9-3.7 volts without vacuum applied, and .5 volt or less with 1.8 in. Hg applied. If voltage is as specified, go to step 12 . If voltage is not as specified, go to next step. 11. Check for an open or short in wiring between vapor pressure sensor and ECM. See WIRING DIAGRAMS article. If problem exists, repair wiring as necessary. If problem does not exist, replace vapor pressure sensor. 12. Check fuel tank and fuel tank overfill valve for damage. If problem exists, repair or replace fuel tank or fuel tank overfill valve as necessary. If problem does not exist, no fault is indicated at this time. Probable cause of DTC to set was an incorrectly installed fuel tank cap.

2002 ENGINE PERFORMANCE Self-Diagnostics - Corolla

Fig. 9: Testing Vapor Pressure Sensor Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. DTC P0441: INCORRECT EVAP PURGE FLOW OR DTC P0446: EVAP VENT CONTROL CIRCUIT CAUTION: If ECM replacement is instructed in following testing, always ensure ECM connectors and ground circuits are okay. If either are suspect, repair and repeat testing to confirm ECM malfunction. NOTE: If DTCs P0110, P0115, P0120, P0440, P0441, P0446, P0450 and P0451 are output together, inspect ECM E2 circuit (sensor ground) between ECM and splice I8. Repair as necessary. See WIRING DIAGRAMS article. If DTC P0441, P0446, P0450 or P0451 is output after DTC P0440 or P0442, perform appropriate test first before performing DTC P0440 test. For component location, see appropriate illustration in THEORY & OPERATION article.

NOTE:

NOTE:

Circuit Description

Vapor pressure sensor, canister closed valve Vacuum Switching Valve (VSV) and pressure switching valve VSV are used to detect faults in EVAP system. DTC is set if EVAP system leak is detected or if there is a malfunction in EVAP VSV, vapor pressure sensor VSV or in vapor pressure sensor. Possible causes are:

Damaged, disconnected or blocked vacuum hose(s). Fuel tank cap is installed incorrectly. Defective fuel tank cap.

2002 ENGINE PERFORMANCE Self-Diagnostics - Corolla

Vapor pressure sensor circuit is open or shorted. Defective vapor pressure sensor. EVAP VSV circuit is open or shorted. Defective EVAP VSV. Canister closed valve VSV circuit is open or shorted. Defective canister closed valve VSV. Pressure switching valve VSV circuit is open or shorted. Defective pressure switching valve VSV. Damaged fuel tank. Defective charcoal canister. Fuel tank overfill valve cracked or damaged. Defective ECM.

Diagnostic Aids

Using scan tool, read FREEZE FRAME data. Freeze frame data records engine conditions when malfunction is detected.
Diagnosis & Repair

1. Check for cracks and deformations in fuel tank, charcoal canister and fuel tank filler pipe. Check for disconnected hoses and tubes around fuel tank and charcoal canister. If problem exists, repair as necessary. If problem does not exist, go to next step. 2. Check fuel tank cap. If fuel tank cap is not an OEM cap, replace fuel tank cap with an OEM cap. If fuel tank cap is an OEM cap, go to next step. 3. Check if fuel tank cap is properly installed. If problem exists, install fuel tank cap properly. If fuel tank cap is properly installed, go to next step. 4. Check for damaged fuel tank cap and gasket. If problem exists, replace fuel tank cap with OEM cap. If problem does not exist, go to next step. 5. Remove fuel tank cap. Visually inspect fuel tank filler neck for damage. If problem exists, replace fuel tank filler neck as necessary. If problem does not exist, go to next step. 6. Check vacuum hoses between vapor pressure sensor and fuel tank, and between charcoal canister and pressure switching valve VSV. Check hoses for correct installation, looseness and damage. If problem exists, repair vacuum hoses as necessary. If problem does not exist, go to next step. 7. Check hose and tube between fuel tank and charcoal canister for correct installation and damage. If problem exists, repair as necessary. If problem does not exist, go to next step. 8. Check all EVAP system electrical component connections. If problem exists, repair as necessary. If problem does not exist, go to next step. 9. Check vacuum hoses between charcoal canister and fuel tank, and between fuel filler neck and fuel tank. If problem exists, repair as necessary. If problem does not exist, go to next step. 10. Access ECM below stereo, behind instrument panel, just in front of center console. See Fig. 2 . Turn ignition on. Using DVOM, backprobe ECM harness connector. On models with 3-speed A/T and M/T, measure voltage between terminals No. 1 (Yellow wire) and No. 9 (Brown wire) at ECM harness connector E5. See Fig. 4 . On models with 4-speed A/T transmission, measure voltage between terminals No. 2 (Yellow wire) and No. 18 (Brown wire) at ECM harness connector E8. See Fig. 5 . On all models, voltage should be 4.5-5.5 volts. If voltage is not as specified, replace ECM. If

2002 ENGINE PERFORMANCE Self-Diagnostics - Corolla

11.

12.

13.

14.

15.

16.

17.

18.

voltage is as specified, go to next step. Using DVOM, backprobe ECM harness connector. On models with 3-speed A/T and M/T, measure voltage between terminal No. 17 (Blue wire) at ECM harness connector E4 and terminal No. 9 (Brown wire) at ECM harness connector E5. On models with 4-speed A/T transmission, measure voltage between terminals No. 9 (Blue wire) and No. 18 (Brown wire) at ECM harness connector E8. On all models, disconnect vacuum hose from vapor pressure sensor. See Fig. 9 . Vapor pressure sensor is mounted on charcoal canister. Connect a vacuum pump to vapor pressure sensor. Voltage should be 2.9-3.7 volts without vacuum applied, and .5 volt or less with 1.8 in. Hg applied. If voltage is as specified, go to step 13 . If voltage is not as specified, go to next step. Check for an open or short in wiring between vapor pressure sensor and ECM. See WIRING DIAGRAMS article. If problem exists, repair wiring as necessary. If problem does not exist, replace vapor pressure sensor. Disconnect EVAP VSV vacuum hoses. Turn ignition on. Access ECM below stereo, behind instrument panel, just in front of center console. See Fig. 2 . On models with 3-speed A/T and M/T, connect a jumper wire by backprobing between ground and terminal No. 7 (Blue/Black wire) at ECM harness connector E4. See Fig. 4 . On models with 4-speed A/T transmission, connect a jumper wire by backprobing between ground and terminal No. 4 (Blue/Black wire) at ECM harness connector E8. See Fig. 5 . On all models, with jumper wire connected air applied to EVAP VSV port "E" should flow from port "F". See Fig. 10 . Remove jumper wire. With jumper wire removed, air applied to EVAP VSV port "E" should not flow from port "F". If EVAP VSV functions as specified, go to step 16 . If EVAP VSV does not function as specified, go to next step. Connect all disconnected components. Check EVAP VSV operation. See FUEL EVAPORATIVE SYSTEM under EMISSION SYSTEMS & SUB-SYSTEMS in SYSTEM & COMPONENT TESTING - 4-CYLINDER article. If EVAP VSV is okay, go to next step. If EVAP VSV is not okay, replace EVAP VSV. Also, clean vacuum hose between throttle body and EVAP VSV, and between EVAP VSV and charcoal canister, then check charcoal canister. See FUEL EVAPORATIVE SYSTEM under EMISSION SYSTEMS & SUB-SYSTEMS in SYSTEM & COMPONENT TESTING - 4-CYLINDER article. Check for an open or short in wiring between engine room junction box and EVAP VSV, and between EVAP VSV and ECM. See WIRING DIAGRAMS article. If problem exists, repair wiring as necessary. If problem does not exist, replace ECM. Disconnect canister closed valve VSV vacuum hoses. Turn ignition on. Access ECM below stereo, behind instrument panel, just in front of center console. See Fig. 2 . On models with 3-speed A/T and M/T, connect a jumper wire by backprobing between ground and terminal No. 5 (Blue/Black wire) at ECM harness connector E4. On models with 4-speed A/T transmission, connect a jumper wire by backprobing between ground and terminal No. 17 (Blue/Black wire) at ECM harness connector E7. On all models, with jumper wire connected air applied to canister closed valve VSV port "B" should not flow from port "A". See Fig. 11 . Remove jumper wire. With jumper wire removed, air applied to canister closed valve VSV port "B" should flow from port "A". If canister closed valve VSV does not function as specified, go to next step. If canister closed valve VSV functions as specified, go to step 19 . Connect all disconnected components. Check canister closed valve VSV. See FUEL EVAPORATIVE SYSTEM under EMISSION SYSTEMS & SUB-SYSTEMS in SYSTEM & COMPONENT TESTING - 4-CYLINDER article. If canister closed valve VSV is okay, go to next step. If canister closed valve VSV is defective, replace canister closed valve VSV and charcoal canister. Also, clean vacuum hose between charcoal canister and canister closed valve VSV. Check for an open or short in wiring between engine room junction box and canister closed valve VSV, and between canister closed valve VSV and ECM. See WIRING DIAGRAMS article. If problem exists, repair wiring as necessary. If problem does not exist, replace ECM.

2002 ENGINE PERFORMANCE Self-Diagnostics - Corolla

19. Disconnect pressure switching valve VSV vacuum hoses. Turn ignition on. Access ECM below stereo, behind instrument panel, just in front of center console. See Fig. 2 . On models with 3-speed A/T and M/T, connect a jumper wire by backprobing between ground and terminal No. 4 (Red wire) at ECM harness connector E4. On models with 4-speed A/T transmission, connect a jumper wire by backprobing between ground and terminal No. 22 (Red wire) at ECM harness connector E7. On all models, with jumper wire connected air applied to pressure switching valve VSV port "E" should flow from port "F". See Fig. 12 . Remove jumper wire. With jumper wire removed, air applied to pressure switching valve VSV port "E" should not flow from port "F". If pressure switching valve VSV functions as specified, go to step 22 . If pressure switching valve VSV does not function as specified, go to next step. 20. Connect all disconnected components. Check pressure switching valve VSV. See FUEL EVAPORATIVE SYSTEM under EMISSION SYSTEMS & SUB-SYSTEMS in SYSTEM & COMPONENT TESTING - 4-CYLINDER article. If pressure switching valve VSV is defective, replace pressure switching valve VSV and charcoal canister. Also, clean vacuum hose between charcoal canister and pressure switching valve VSV, and between pressure switching valve VSV and fuel tank. If pressure switching valve VSV is okay, go to next step. 21. Check for an open or short in wiring between engine room junction box and pressure switching valve VSV, and between pressure switching valve VSV and ECM. See WIRING DIAGRAMS article. If problem exists, repair wiring as necessary. If problem does not exist, replace ECM. 22. Connect all disconnected components. Charcoal canister or fuel tank overfill check valve maybe defective. Check fuel evaporative system. See FUEL EVAPORATIVE SYSTEM under EMISSION SYSTEMS & SUB-SYSTEMS in SYSTEM & COMPONENT TESTING - 4-CYLINDER article. Repair as necessary.

2002 ENGINE PERFORMANCE Self-Diagnostics - Corolla

Fig. 10: Identifying EVAP VSV Vacuum Ports Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 ENGINE PERFORMANCE Self-Diagnostics - Corolla

Fig. 11: Identifying Canister Closed Valve VSV Vacuum Ports Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 ENGINE PERFORMANCE Self-Diagnostics - Corolla

Fig. 12: Identifying Pressure Switching Valve VSV Vacuum Ports Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. DTC P0450: EVAP PRESSURE SENSOR CIRCUIT OR DTC P0451: EVAP PRESSURE SENSOR RANGE/PERFORMANCE CAUTION: If ECM replacement is instructed in following testing, always ensure ECM connectors and ground circuits are okay. If either are suspect, repair and repeat testing to confirm ECM malfunction. NOTE: If DTCs P0110, P0115, P0120, P0440, P0441, P0446, P0450 and P0451 are output together, inspect ECM E2 circuit (sensor ground) between ECM and splice I8. Repair as necessary. See WIRING DIAGRAMS article. If DTC P0441, P0446, P0450 or P0451 is output after DTC P0440 or P0442, perform appropriate test first before performing DTC P0440 test. For component location, see appropriate illustration in THEORY & OPERATION article.

NOTE:

NOTE:

Circuit Description

Vapor pressure sensor, canister closed valve Vacuum Switching Valve (VSV) and pressure switching valve VSV are used to detect faults in EVAP system. DTC is set if vapor pressure sensor malfunctions. Possible

2002 ENGINE PERFORMANCE Self-Diagnostics - Corolla

causes are:

Vapor pressure sensor circuit is open or shorted. Defective vapor pressure sensor. Defective ECM.

Diagnostic Aids

Using scan tool, read FREEZE FRAME data. Freeze frame data records engine conditions when malfunction is detected.
Diagnosis & Repair

1. Access ECM below stereo, behind instrument panel, just in front of center console. See Fig. 2 . Turn ignition on. Using DVOM, backprobe ECM harness connector. On models with 3-speed A/T and M/T, measure voltage between terminals No. 1 (Yellow wire) and No. 9 (Brown wire) at ECM harness connector E5. See Fig. 4 . On models with 4-speed A/T transmission, measure voltage between terminals No. 2 (Yellow wire) and No. 18 (Brown wire) at ECM harness connector E8. See Fig. 5 . On all models, voltage should be 4.5-5.5 volts. If voltage is not as specified, replace ECM. If voltage is as specified, go to next step. 2. Using DVOM, backprobe ECM harness connector. On models with 3-speed A/T and M/T, measure voltage between terminal No. 17 (Blue wire) at ECM harness connector E4 and terminal No. 9 (Brown wire) at ECM harness connector E5. On models with 4-speed A/T transmission, measure voltage between terminals No. 9 (Blue wire) and No. 18 (Brown wire) at ECM harness connector E8. On all models, disconnect vacuum hose from vapor pressure sensor. See Fig. 9 . Connect a vacuum pump to vapor pressure sensor. Voltage should be 2.9-3.7 volts without vacuum applied, and .5 volt or less with 1.8 in. Hg applied. If voltage is as specified, replace ECM. If voltage is not as specified, go to next step. 3. Check for open or short in wiring between vapor pressure sensor and ECM. See WIRING DIAGRAMS article. If problem exists, repair wiring as necessary. If problem does not exist, replace vapor pressure sensor. DTC P0500: VEHICLE SPEED SENSOR CIRCUIT CAUTION: If ECM replacement is instructed in following testing, always ensure ECM connectors and ground circuits are okay. If either are suspect, repair and repeat testing to confirm ECM malfunction. NOTE: For component location, see appropriate illustration in THEORY & OPERATION article.

Circuit Description

VSS outputs a 4-pulse signal for every revolution of rotor shaft, which is driven by transaxle output shaft. Signal is sent to instrument cluster to operate speedometer. Instrument cluster then sends signal to ECM. Signal is used by ECM to determine vehicle speed. DTC is set if there is no VSS signal to ECM while vehicle is being driven and park/neutral switch is off. Possible causes are:

Defective vehicle speed sensor.

2002 ENGINE PERFORMANCE Self-Diagnostics - Corolla

Vehicle speed sensor circuit is open or shorted. Defective instrument cluster. Defective ECM.

Diagnostic Aids

Using scan tool, read FREEZE FRAME data. Freeze frame data records engine conditions when malfunction is detected.
Diagnosis & Repair

1. Test drive vehicle and check operation of speedometer. If speedometer is not operating correctly, repair speedometer as necessary. See appropriate INSTRUMENT PANELS article in ACCESSORIES & EQUIPMENT. If speedometer is operating correctly, go to next step. 2. Access ECM below stereo, behind instrument panel, just in front of center console. See Fig. 2 . Raise and support one front wheel. Turn ignition on. Shift transaxle lever into Neutral. Using DVOM, backprobe ECM harness connector. On models with 3-speed A/T and M/T, measure voltage between ground and terminal No. 9 (Violet/White wire) at ECM harness connector E6. See Fig. 4 . On models with 4-speed A/T transmission, measure voltage between ground and terminal No. 22 (Violet/White wire) at ECM harness connector E9. See Fig. 5 . On all models, observe voltage reading while rotating front wheel. Voltage should pulse between zero volts and 4.5-5.5 volts. If voltage is as specified, replace ECM. If voltage is not as specified, repair open or short in wiring between instrument cluster and ECM. See WIRING DIAGRAMS article. DTC P0505: IDLE AIR CONTROL SYSTEM CIRCUIT CAUTION: If ECM replacement is instructed in following testing, always ensure ECM connectors and ground circuits are okay. If either are suspect, repair and repeat testing to confirm ECM malfunction.
Circuit Description

ECM operates Idle Air Control (IAC) valve to perform idle-up and provide feedback for target idling speed. DTC is set when idle speed continues to vary greatly from target speed. Possible causes are:

Idle Air Control (IAC) valve is stuck, or remains closed. IAC valve circuit is open or shorted. A/C switch circuit is open or shorted. Air induction system malfunction. Defective ECM.

Diagnostic Aids

Using scan tool, read FREEZE FRAME data. Freeze frame data records engine conditions when malfunction is detected.
Diagnosis & Repair (Using Toyota Hand-Held Tester)

1. Connect hand-held tester to Data Link Connector (DLC) No. 3. See Fig. 1 . Start engine and warm to

2002 ENGINE PERFORMANCE Self-Diagnostics - Corolla

2. 3.

4. 5.

6.

7.

8.

normal operating temperature. Turn all accessories off. Ensure A/C is off. Place transmission in Neutral. Note idle speed. Using hand-held tester, select ACTIVE TEST mode and switch TE1 on. Note engine RPM and compare RPM readings. If difference in engine speed is more than 100 RPM, go to step 8 . If difference in engine speed is 100 RPM or less, go to next step. Turn ignition off. Turn ignition on. Using hand-held tester, check IAC valve duty ratio. If duty ratio is 27-47 percent, go to next step. If duty ratio is not 27-47 percent, replace ECM. Check operation of IAC valve. See IDLE CONTROL SYSTEMS in SYSTEM & COMPONENT TESTING - 4-CYLINDER article. If IAC valve does not operate properly, go to step 5 . If IAC valve operates properly, go to next step. Remove IAC valve from throttle body. Check IAC valve and passages for carbon build-up and blockage. If problem exists, repair or replace as necessary. If problem does not exist, go to step 8 . Turn ignition off. Disconnect IAC valve harness connector. Turn ignition on. Measure voltage between ground and terminal No. 2 (Black wire) at IAC valve harness connector. If voltage is 9-14 volts, go to next step. If voltage is not 9-14 volts, repair power distribution circuit as necessary. See WIRING DIAGRAMS article. Check for open in Brown wire between ground and terminal No. 3 at IAC valve harness connector. See WIRING DIAGRAMS article. If problem exists, repair wiring as necessary. If problem does not exist, go to next step. Check for open or short in Black/Blue wire between IAC valve and ECM. See WIRING DIAGRAMS article. If problem exists, repair wiring as necessary. If problem does not exist, replace IAC valve. Ensure oil dipstick, oil filler cap, PCV system and all other air induction system components are intact and operating properly. If problem exists, repair as necessary. If problem does not exist, an open or short in A/C switch signal circuit may exist. Check A/C amplifier. See MANUAL COROLLA article in AIR CONDITIONING & HEATING. Repair as necessary.

Diagnosis & Repair (Using OBD-II Scan Tool)

1. Start engine and warm to normal operating temperature. Turn all accessories off. Ensure A/C is off. Shift transaxle lever into Neutral. Connect scan tool to Data Link Connector (DLC) No. 3. See Fig. 1 . Note engine RPM. Using a jumper wire, connect terminals TE1 and E1 at DLC No. 1 in engine compartment. See Fig. 13 . Note engine RPM and compare RPM readings. If difference in engine speed is more than 100 RPM, go to step 9 . If difference in engine speed is 100 RPM or less, go to next step. 2. Turn ignition off. Access ECM below stereo, behind instrument panel, just in front of center console. See Fig. 2 . On models with 3-speed A/T and M/T, connect an oscilloscope by backprobing between ground and terminal No. 15 (Blue/Black wire) at ECM harness connector E4. See Fig. 4 . On models with 4-speed A/T transmission, connect an oscilloscope by backprobing between ground and terminal No. 18 (Blue/Black wire) at ECM harness connector E7. See Fig. 5 . On all models, start engine and let idle. Oscilloscope waveform should be as illustrated. See Fig. 14 . If waveform is as shown, go to step 6 . If waveform is not as shown, go to next step. 3. Turn ignition off. Turn ignition on. Using DVOM, backprobe ECM harness connector. On models with 3-speed A/T and M/T, measure voltage between ground and terminal No. 15 (Blue/Black wire) at ECM harness connector E4. On models with 4-speed A/T transmission, measure voltage between ground and terminal No. 18 (Blue/Black wire) at ECM harness connector E7. On all models, voltage should be 9-14 volts. If voltage is as specified, replace ECM. If voltage is not as specified, go to next step. 4. Turn ignition off. Disconnect IAC valve harness connector. Measure voltage between ground and terminal No. 2 (Black wire) at IAC valve harness connector. If voltage is 9-14 volts, go to next step. If

2002 ENGINE PERFORMANCE Self-Diagnostics - Corolla

5.

6.

7.

8. 9.

voltage is not 9-14 volts, repair IAC valve power distribution circuit. See WIRING DIAGRAMS article. Check for open or short in Blue/Black wire between IAC valve and ECM. See WIRING DIAGRAMS article. If problem exists, repair wiring as necessary. If problem does not exist, replace IAC valve. Check IAC valve operation. See IDLE CONTROL SYSTEMS in SYSTEM & COMPONENT TESTING - 4-CYLINDER article. If problem exists, go to next step. If problem does not exist, go to step 8 . Check for open in Brown wire between ground and terminal No. 3 at IAC valve harness connector. See WIRING DIAGRAMS article. If problem exists, repair wiring as necessary. If problem does not exist, replace IAC valve. Remove IAC valve from throttle body. Check IAC valve and passages for carbon build-up and blockage. If problem exists, repair or replace as necessary. If problem does not exist, go to next step. Ensure oil dipstick, oil filler cap, PCV system and all other air induction system components are intact and operating properly. If problem exists, repair as necessary. If problem does not exist, an open or short in A/C switch signal circuit may exist. Check A/C amplifier. See MANUAL COROLLA article in AIR CONDITIONING & HEATING. Repair as necessary.

Fig. 13: Installing Jumper Wire Between Data Link Connector No. 1 Terminals Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 ENGINE PERFORMANCE Self-Diagnostics - Corolla

Fig. 14: Identifying Idle Air Control Valve Waveform Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. DTC P1300: IGNITOR NO. 1 CIRCUIT CAUTION: If ECM replacement is instructed in following testing, always ensure ECM connectors and ground circuits are okay. If either are suspect, repair and repeat testing to confirm ECM malfunction.
Circuit Description

Direct Ignition System (DIS) is a one-cylinder ignition system that ignites one cylinder with one ignition coil. Ignitor is integral to ignition coil. ECM determines ignition timing and outputs an ignition signal (IGT) for each cylinder. Based on IGT signals, power transistors in the ignitor cut off current to primary coil in ignition coil, causing ignition coil to fire spark plug. After delivering a command to turn off primary circuit on IGT wire, ECM monitors IGF circuit to ensure primary switching occurred. DTC P1300 is for ignition coil No. 1 and is set when there is no IGF signal to ECM during engine operation. ECM will operate in failsafe mode if DTC P1300 is set. Possible causes are:

Ignition system malfunction. IGF or IGT1 circuit from ignitor to ECM is open or shorted. Defective ignition coil/ignitor No. 1. Defective ECM.

Diagnostic Aids

Using scan tool, read FREEZE FRAME data. Freeze frame data records engine conditions when

2002 ENGINE PERFORMANCE Self-Diagnostics - Corolla

malfunction is detected.
Diagnosis & Repair

1. Check for spark at misfiring cylinder. See IGNITION SYSTEMS in BASIC DIAGNOSTIC PROCEDURES - 4-CYLINDER article. If spark exists, go to next step. If spark does not exist, go to step 4 . 2. Check for open or short in Blue/Yellow wire between ECM and ignition coil/ignitor No. 1. Also, check for open or short in Red/Blue wire between ECM and ignition coil/ignitor No. 1. See WIRING DIAGRAMS article. If problem exists, repair wiring as necessary. If problem does not exist, go to next step. 3. Disconnect ignition coil/ignitor No. 1 harness connector. Access ECM below stereo, behind instrument panel, just in front of center console. See Fig. 2 . Turn ignition on. Using DVOM, backprobe at ECM harness connector. On models with 3-speed A/T and M/T, measure voltage between ground and terminal No. 3 (Blue/Yellow wire) at ECM harness connector E4. See Fig. 4 . On models with 4-speed A/T transmission, measure voltage between ground and terminal No. 25 (Blue/Yellow wire) at ECM harness connector E7. See Fig. 5 . On all models, voltage should be 4.55.5 volts. If voltage is as specified, replace ignition coil/ignitor No. 1. If voltage is not as specified, replace ECM. 4. Check for open or short in Red/Blue wire between ECM and ignition coil/ignitor No. 1. See WIRING DIAGRAMS article. If problem exists, repair wiring as necessary. If problem does not exist, go to next step. 5. Access ECM below stereo, behind instrument panel, just in front of center console. See Fig. 2 . Using DVOM, backprobe ECM harness connector. On models with 3-speed A/T and M/T, measure voltage between ground and terminal No. 20 (Red/Blue wire) at ECM harness connector E4 while cranking engine. See Fig. 4 . On models with 4-speed A/T transmission, measure voltage between ground and terminal No. 10 (Red/Blue wire) at ECM harness connector E7 while cranking engine. See Fig. 5 . On all models, voltage should be .1-4.5 volts. If voltage is not as specified, go to next step. If voltage is as specified, go to step 7 . 6. Disconnect ignition coil/ignitor No. 1 harness connector. Using DVOM, backprobe ECM harness connector. On models with 3-speed A/T and M/T, measure voltage between ground and terminal No. 20 (Red/Blue wire) at ECM harness connector E4 while cranking engine. On models with 4-speed A/T transmission, measure voltage between ground and terminal No. 10 (Red/Blue wire) at ECM harness connector E7 while cranking engine. On all models, voltage should be .1-5.0 volts. If voltage is as specified, replace ignition coil/ignitor No. 1. If voltage is not as specified, replace ECM 7. Turn ignition on. Measure voltage between ground and terminal No. 1 (Black/White wire) at ignition coil/ignitor No. 1 harness connector. See Fig. 15 . If voltage is 9-14 volts, go to next step. If voltage is not 9-14 volts, check and repair ignition coil/ignitor No. 1 power source circuit. See WIRING DIAGRAMS article. 8. Check for open or short in wiring between ground and terminal No. 4 (Brown wire) at ignition coil/ignitor No. 1 harness connector. See WIRING DIAGRAMS article. If problem exists, repair wiring as necessary. If problem does not exist, replace ignition coil/ignitor No. 1.

2002 ENGINE PERFORMANCE Self-Diagnostics - Corolla

Fig. 15: Identifying Ignition Coil/Ignitor Harness Connector Terminals Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. DTC P1305: IGNITOR NO. 2 CIRCUIT CAUTION: If ECM replacement is instructed in following testing, always ensure ECM connectors and ground circuits are okay. If either are suspect, repair and repeat testing to confirm ECM malfunction.
Circuit Description

Direct Ignition System (DIS) is a one-cylinder ignition system that ignites one cylinder with one ignition coil. Ignitor is integral to ignition coil. ECM determines ignition timing and outputs an ignition signal (IGT) for each cylinder. Based on IGT signals, power transistors in the ignitor cut off current to primary coil in ignition coil, causing ignition coil to fire spark plug. After delivering a command to turn off primary circuit on IGT wire, ECM monitors IGF circuit to ensure primary switching occurred. DTC P1305 is for ignition coil No. 2 and is set when there is no IGF signal to ECM during engine operation. ECM will operate in failsafe mode if DTC P1305 is set. Possible causes are:

Ignition system malfunction. IGF or IGT2 circuit from ignitor to ECM is open or shorted. Defective ignition coil/ignitor No. 2. Defective ECM.

Diagnostic Aids

Using scan tool, read FREEZE FRAME data. Freeze frame data records engine conditions when malfunction is detected.
Diagnosis & Repair

2002 ENGINE PERFORMANCE Self-Diagnostics - Corolla

1. Check for spark at misfiring cylinder. See IGNITION SYSTEMS in BASIC DIAGNOSTIC PROCEDURES - 4-CYLINDER article. If spark exists, go to next step. If spark does not exist, go to step 4 . 2. Check for open or short in Blue/Yellow wire between ECM and ignition coil/ignitor No. 2. Also, check for open or short in Yellow/Green wire between ECM and ignition coil/ignitor No. 2. See WIRING DIAGRAMS article. If problem exists, repair wiring as necessary. If problem does not exist, go to next step. 3. Disconnect ignition coil/ignitor No. 2 harness connector. Access ECM below stereo, behind instrument panel, just in front of center console. See Fig. 2 . Turn ignition on. Using DVOM, backprobe at ECM harness connector. On models with 3-speed A/T and M/T, measure voltage between ground and terminal No. 3 (Blue/Yellow wire) at ECM harness connector E4. See Fig. 4 . On models with 4-speed A/T transmission, measure voltage between ground and terminal No. 25 (Blue/Yellow wire) at ECM harness connector E7. See Fig. 5 . On all models, voltage should be 4.55.5 volts. If voltage is as specified, replace ignition coil/ignitor No. 2. If voltage is not as specified, replace ECM. 4. Check for open or short in Yellow/Green wire between ECM and ignition coil/ignitor No. 2. See WIRING DIAGRAMS article. If problem exists, repair wiring as necessary. If problem does not exist, go to next step. 5. Access ECM below stereo, behind instrument panel, just in front of center console. See Fig. 2 . Using DVOM, backprobe ECM harness connector. On models with 3-speed A/T and M/T, measure voltage between ground and terminal No. 21 (Yellow/Green wire) at ECM harness connector E4 while cranking engine. See Fig. 4 . On models with 4-speed A/T transmission, measure voltage between ground and terminal No. 11 (Yellow/Green wire) at ECM harness connector E7 while cranking engine. See Fig. 5 . On all models, voltage should be .1-4.5 volts. If voltage is not as specified, go to next step. If voltage is as specified, go to step 7 . 6. Disconnect ignition coil/ignitor No. 2 harness connector. Using DVOM, backprobe ECM harness connector. On models with 3-speed A/T and M/T, measure voltage between ground and terminal No. 21 (Yellow/Green wire) at ECM harness connector E4 while cranking engine. On models with 4speed A/T transmission, measure voltage between ground and terminal No. 11 (Yellow/Green wire) at ECM harness connector E7 while cranking engine. On all models, voltage should be .1-5.0 volts. If voltage is as specified, replace ignition coil/ignitor No. 2. If voltage is not as specified, replace ECM. 7. Turn ignition on. Measure voltage between ground and terminal No. 1 (Black/White wire) at ignition coil/ignitor No. 2 harness connector. See Fig. 15 . If voltage is 9-14 volts, go to next step. If voltage is not 9-14 volts, check and repair ignition coil/ignitor No. 2 power source circuit. See WIRING DIAGRAMS article. 8. Check for open or short in wiring between ground and terminal No. 4 (Brown wire) at ignition coil/ignitor No. 2 harness connector. See WIRING DIAGRAMS article. If problem exists, repair wiring as necessary. If problem does not exist, replace ignition coil/ignitor No. 2. DTC P1310: IGNITOR NO. 3 CIRCUIT CAUTION: If ECM replacement is instructed in following testing, always ensure ECM connectors and ground circuits are okay. If either are suspect, repair and repeat testing to confirm ECM malfunction.
Circuit Description

Direct Ignition System (DIS) is a one-cylinder ignition system that ignites one cylinder with one ignition coil. Ignitor is integral to ignition coil. ECM determines ignition timing and outputs an ignition signal (IGT)

2002 ENGINE PERFORMANCE Self-Diagnostics - Corolla

for each cylinder. Based on IGT signals, power transistors in the ignitor cut off current to primary coil in ignition coil, causing ignition coil to fire spark plug. After delivering a command to turn off primary circuit on IGT wire, ECM monitors IGF circuit to ensure primary switching occurred. DTC P1310 is for ignition coil No. 3 and is set when there is no IGF signal to ECM during engine operation. ECM will operate in failsafe mode if DTC P1310 is set. Possible causes are:

Ignition system malfunction. IGF or IGT3 circuit from ignitor to ECM is open or shorted. Defective ignition coil/ignitor No. 3. Defective ECM.

Diagnostic Aids

Using scan tool, read FREEZE FRAME data. Freeze frame data records engine conditions when malfunction is detected.
Diagnosis & Repair

1. Check for spark at misfiring cylinder. See IGNITION SYSTEMS in BASIC DIAGNOSTIC PROCEDURES - 4-CYLINDER article. If spark exists, go to next step. If spark does not exist, go to step 4 . 2. Check for open or short in Blue/Yellow wire between ECM and ignition coil/ignitor No. 3. Also, check for open or short in Gray wire between ECM and ignition coil/ignitor No. 3. See WIRING DIAGRAMS article. If problem exists, repair wiring as necessary. If problem does not exist, go to next step. 3. Disconnect ignition coil/ignitor No. 3 harness connector. Access ECM below stereo, behind instrument panel, just in front of center console. See Fig. 2 . Turn ignition on. Using DVOM, backprobe at ECM harness connector. On models with 3-speed A/T and M/T, measure voltage between ground and terminal No. 3 (Blue/Yellow wire) at ECM harness connector E4. See Fig. 4 . On models with 4-speed A/T transmission, measure voltage between ground and terminal No. 25 (Blue/Yellow wire) at ECM harness connector E7. See Fig. 5 . On all models, voltage should be 4.55.5 volts. If voltage is as specified, replace ignition coil/ignitor No. 3. If voltage is not as specified, replace ECM. 4. Check for open or short in Gray wire between ECM and ignition coil/ignitor No. 3. See WIRING DIAGRAMS article. If problem exists, repair wiring as necessary. If problem does not exist, go to next step. 5. Access ECM below stereo, behind instrument panel, just in front of center console. See Fig. 2 . Using DVOM, backprobe ECM harness connector. On models with 3-speed A/T and M/T, measure voltage between ground and terminal No. 22 (Gray wire) at ECM harness connector E4 while cranking engine. See Fig. 4 . On models with 4-speed A/T transmission, measure voltage between ground and terminal No. 12 (Gray wire) at ECM harness connector E7 while cranking engine. See Fig. 5 . On all models, voltage should be .1-4.5 volts. If voltage is not as specified, go to next step. If voltage is as specified, go to step 7 . 6. Disconnect ignition coil/ignitor No. 3 harness connector. Using DVOM, backprobe ECM harness connector. On models with 3-speed A/T and M/T, measure voltage between ground and terminal No. 22 (Gray wire) at ECM harness connector E4 while cranking engine. On models with 4-speed A/T transmission, measure voltage between ground and terminal No. 12 (Gray wire) at ECM harness connector E7 while cranking engine. On all models, voltage should be .1-5.0 volts. If voltage is as specified, replace ignition coil/ignitor No. 3. If voltage is not as specified, replace ECM.

2002 ENGINE PERFORMANCE Self-Diagnostics - Corolla

7. Turn ignition on. Measure voltage between ground and terminal No. 1 (Black/White wire) at ignition coil/ignitor No. 3 harness connector. See Fig. 15 . If voltage is 9-14 volts, go to next step. If voltage is not 9-14 volts, check and repair ignition coil/ignitor No. 3 power source circuit. See WIRING DIAGRAMS article. 8. Check for open or short in wiring between ground and terminal No. 4 (Brown wire) at ignition coil/ignitor No. 3 harness connector. See WIRING DIAGRAMS article. If problem exists, repair wiring as necessary. If problem does not exist, replace ignition coil/ignitor No. 3. DTC P1315: IGNITOR NO. 4 CIRCUIT CAUTION: If ECM replacement is instructed in following testing, always ensure ECM connectors and ground circuits are okay. If either are suspect, repair and repeat testing to confirm ECM malfunction.
Circuit Description

Direct Ignition System (DIS) is a one-cylinder ignition system that ignites one cylinder with one ignition coil. Ignitor is integral to ignition coil. ECM determines ignition timing and outputs an ignition signal (IGT) for each cylinder. Based on IGT signals, power transistors in the ignitor cut off current to primary coil in ignition coil, causing ignition coil to fire spark plug. After delivering a command to turn off primary circuit on IGT wire, ECM monitors IGF circuit to ensure primary switching occurred. DTC P1315 is for ignition coil No. 4 and is set when there is no IGF signal to ECM during engine operation. ECM will operate in failsafe mode if DTC P1315 is set. Possible causes are:

Ignition system malfunction. IGF or IGT4 circuit from ignitor to ECM is open or shorted. Defective ignition coil/ignitor No. 4. Defective ECM.

Diagnostic Aids

Using scan tool, read FREEZE FRAME data. Freeze frame data records engine conditions when malfunction is detected.
Diagnosis & Repair

1. Check for spark at misfiring cylinder. See IGNITION SYSTEMS in BASIC DIAGNOSTIC PROCEDURES - 4-CYLINDER article. If spark exists, go to next step. If spark does not exist, go to step 4 . 2. Check for open or short in Blue/Yellow wire between ECM and ignition coil/ignitor No. 4. Also, check for open or short in White wire between ECM and ignition coil/ignitor No. 4. See WIRING DIAGRAMS article. If problem exists, repair wiring as necessary. If problem does not exist, go to next step. 3. Disconnect ignition coil/ignitor No. 4 harness connector. Access ECM below stereo, behind instrument panel, just in front of center console. See Fig. 2 . Turn ignition on. Using DVOM, backprobe at ECM harness connector. On models with 3-speed A/T and M/T, measure voltage between ground and terminal No. 3 (Blue/Yellow wire) at ECM harness connector E4. See Fig. 4 . On models with 4-speed A/T transmission, measure voltage between ground and terminal No. 25 (Blue/Yellow wire) at ECM harness connector E7. See Fig. 5 . On all models, voltage should be 4.5-

2002 ENGINE PERFORMANCE Self-Diagnostics - Corolla

4.

5.

6.

7.

8.

5.5 volts. If voltage is as specified, replace ignition coil/ignitor No. 4. If voltage is not as specified, replace ECM. Check for open or short in White wire between ECM and ignition coil/ignitor No. 4. See WIRING DIAGRAMS article. If problem exists, repair wiring as necessary. If problem does not exist, go to next step. Access ECM below stereo, behind instrument panel, just in front of center console. See Fig. 2 . Using DVOM, backprobe ECM harness connector. On models with 3-speed A/T and M/T, measure voltage between ground and terminal No. 23 (White wire) at ECM harness connector E4 while cranking engine. See Fig. 4 . On models with 4-speed A/T transmission, measure voltage between ground and terminal No. 13 (White wire) at ECM harness connector E7 while cranking engine. See Fig. 5 . On all models, voltage should be .1-4.5 volts. If voltage is not as specified, go to next step. If voltage is as specified, go to step 7 . Disconnect ignition coil/ignitor No. 4 harness connector. Using DVOM, backprobe ECM harness connector. On models with 3-speed A/T and M/T, measure voltage between ground and terminal No. 23 (White wire) at ECM harness connector E4 while cranking engine. On models with 4-speed A/T transmission, measure voltage between ground and terminal No. 13 (White wire) at ECM harness connector E7 while cranking engine. On all models, voltage should be .1-5.0 volts. If voltage is as specified, replace ignition coil/ignitor No. 4. If voltage is not as specified, replace ECM. Turn ignition on. Measure voltage between ground and terminal No. 1 (Black/White wire) at ignition coil/ignitor No. 4 harness connector. See Fig. 15 . If voltage is 9-14 volts, go to next step. If voltage is not 9-14 volts, check and repair ignition coil/ignitor No. 4 power source circuit. See WIRING DIAGRAMS article. Check for open or short in wiring between ground and terminal No. 4 (Brown wire) at ignition coil/ignitor No. 4 harness connector. See WIRING DIAGRAMS article. If problem exists, repair wiring as necessary. If problem does not exist, replace ignition coil/ignitor No. 4.

DTC P1335: CRANKSHAFT POSITION SENSOR CIRCUIT See DTC P0335 OR P1335: CRANKSHAFT POSITION SENSOR CIRCUIT test. DTC P1346: VARIABLE VALVE TIMING CIRCUIT RANGE/PERFORMANCE CAUTION: If ECM replacement is instructed in following testing, always ensure ECM connectors and ground circuits are okay. If either are suspect, repair and repeat testing to confirm ECM malfunction. NOTE: Variable Valve Timing (VVT) sensor may also be referred to as camshaft position sensor. Bank No. 1 refers to bank which includes cylinder No. 1. Bank No. 2 refers to bank without cylinder No. 1.

NOTE:

Circuit Description

The Variable Valve Timing (VVT) sensor consists of a signal plate and pick-up coil. The signal plate has one tooth and is mounted on intake camshaft. The VVT sensor provides feedback to ECM in order to control intake valve timing. DTC is set when ECM detects a deviation in crankshaft position sensor and VVT sensor. Possible causes are:

2002 ENGINE PERFORMANCE Self-Diagnostics - Corolla

Mechanical system malfunction (timing belt stretched of timing belt teeth jumped). Defective ECM.

Diagnostic Aids

Using scan tool, read FREEZE FRAME data. Freeze frame data records engine conditions when malfunction is detected.
Diagnosis & Repair

Check valve timing. Check for loose, stretched or jumped teeth of timing belt. See appropriate article in ENGINES. If problem exists, repair as necessary. If problem does not exist, replace ECM. DTC P1349: VARIABLE VALVE TIMING SYSTEM MALFUNCTION CAUTION: If ECM replacement is instructed in following tests, always ensure ECM connectors and ground circuits are okay. If either are suspect, repair and repeat testing to confirm ECM malfunction.
Circuit Description

The Variable Valve Timing (VVT) system controls intake valve timing in response to driving conditions. Engine Control Module (ECM) controls Variable Valve Timing (VVT) Oil Control Valve (OCV) to ensure correct valve timing. VVT OCV is located on timing chain side of cylinder head, next to intake manifold. Oil pressure controlled by the VVT OCV is supplied to the VVT controller. VVT controller then changes relative position between camshaft and crankshaft. VVT controller is located on the front of intake camshaft. DTC P1349 is set if ECM detects valve timing does not change (fixed timing). Possible causes are:

Incorrect valve timing. Defective Variable Valve Timing (VVT) Oil Control Valve (OCV). Defective VVT controller assembly. Defective ECM.

Diagnostic Aids

Using scan tool, read FREEZE FRAME data. Freeze frame data records engine conditions when malfunction is detected.
Diagnosis & Repair (Using Toyota Hand-Held Tester)

1. Check valve timing. See appropriate article in ENGINES. If problem exists, repair as necessary. If problem does not exist, go to next step. 2. Connect hand-held tester to Data Link Connector (DLC) No. 3. See Fig. 1 . Using hand-held tester, select ACTIVE TEST mode. Select VVT. Note idle speed when VVT OCV is activated by hand-held tester. Idle speed should be normal with VVT OCV off, and engine should idle rough or stalls when VVT OCV is on. If idle speed functions as specified, VVT is functioning properly at this time. DTC may have been set because of a foreign object that was temporarily caught in the engine oil system but after a short time system returned to normal. If idle speed does not function as specified, go to next step.

2002 ENGINE PERFORMANCE Self-Diagnostics - Corolla

3. Access ECM below stereo, behind instrument panel, just in front of center console. See Fig. 2 . Using oscilloscope, backprobe ECM harness connector. On models with 3-speed A/T and M/T, connect oscilloscope between terminals No. 1 (Red wire) and No. 2 (Black wire) at ECM harness connector E4. See Fig. 4 . On models with 4-speed A/T transmission, connect oscilloscope between terminals No. 23 (Red wire) and No. 24 (Black wire) at ECM harness connector E7. See Fig. 5 . On all models, start engine and let idle. Ensure oscilloscope pattern is as shown in illustration. See Fig. 16 . As engine speed is increased, waveform frequency ("A") should lengthen. If waveform pattern is as shown, go to next step. If waveform pattern is not as shown, replace ECM. 4. Turn ignition off. Check VVT controller assembly for proper operation. See appropriate article in ENGINES. If problem exists, replace VVT controller assembly and go to next step. If problem does not exist, go to next step. 5. Disconnect VVT OCV harness connector. Measure resistance between VVT OCV terminals (component side). Resistance should be 6.9-7.9 ohms at 68F (20C). If resistance is as specified, go to next step. If resistance is not as specified, replace VVT OCV. 6. Remove VVT OCV. Connect a fused jumper wire between positive battery terminal and terminal No. 1 at VVT OCV. See Fig. 17 . Connect another jumper wire between negative battery terminal and terminal No. 2 at VVT OCV and note VVT OCV plunger operation. With battery voltage applied, plunger on end of VVT OCV should extend. Disconnect a jumper wire. Without battery voltage applied, plunger should retract. If VVT OCV operates as specified, go to next step. If VVT OCV does not operate as specified, replace VVT OCV and go to next step. 7. Check blockage in VVT OCV. Check oil check valve and oil pipe located under VVT OCV. If problem exists, repair as necessary. If problem does not exist, go to next step. 8. Install all remove components and connect all disconnected harness connectors. Using hand-held tester, clear DTCs. Start engine and allow it to idle. Turn ignition off. Turn ignition on and check for DTCs. If DTC P1349 is not present, no problem is indicated at this time. DTC may have been set because of a foreign object that was temporarily caught in the engine oil system but after a short time system returned to normal. If DTC P1349 is present, replace ECM.

2002 ENGINE PERFORMANCE Self-Diagnostics - Corolla

Fig. 16: Oil Control Valve Signal Waveform Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 ENGINE PERFORMANCE Self-Diagnostics - Corolla

Fig. 17: Testing Oil Control Valve Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Diagnosis & Repair (Using OBD-II Scan Tool)

1. Check valve timing. See appropriate article in ENGINES. If problem exists, repair as necessary. If problem does not exist, go to next step. 2. Start engine and allow it to idle. Disconnect Variable Valve Timing (VVT) Oil Control Valve (OCV) and note idle speed. VVT OCV is located on front cylinder head, next to intake manifold. Engine idle speed should not change. Using jumper wires, apply battery voltage and ground to VVT OCV terminals (component side). Engine should idle rough or stall. If VVT OCV operates as specified, go to next step. If VVT OCV does not operate as specified, go to step 4 . 3. Turn ignition off. Connect VVT OCV harness connector. Access ECM below stereo, behind instrument panel, just in front of center console. See Fig. 2 . Using oscilloscope, backprobe ECM harness connector. On models with 3-speed A/T and M/T, connect oscilloscope between terminals No. 1 (Red wire) and No. 2 (Black wire) at ECM harness connector E4. See Fig. 4 . On models with 4-speed A/T transmission, connect oscilloscope between terminals No. 23 (Red wire) and No. 24 (Black wire) at ECM harness connector E7. See Fig. 5 . On all applications, start engine and let idle. Ensure oscilloscope pattern is as shown in illustration. See Fig. 16 . As engine speed is increased, waveform frequency ("A") should lengthen. If waveform pattern is as shown, no problem is indicated at this time. DTC may have been set because of a foreign object that was temporarily caught in the engine oil system but after a short time system returned to normal. If waveform pattern is not as shown, replace ECM. 4. Check VVT controller assembly for proper operation. See appropriate article in ENGINES. If problem exists, replace VVT controller assembly and go to next step. If problem does not exist, go to next step.

2002 ENGINE PERFORMANCE Self-Diagnostics - Corolla

5. Disconnect VVT OCV harness connector. Measure resistance between VVT OCV terminals (component side). Resistance should be 6.9-7.9 ohms at 68F (20C). If resistance is as specified, go to next step. If resistance is not as specified, replace VVT OCV. 6. Remove VVT OCV. Connect a fused jumper wire between positive battery terminal and terminal No. 1 at VVT OCV. See Fig. 17 . Connect another jumper wire between negative battery terminal and terminal No. 2 at VVT OCV and note VVT OCV plunger operation. With battery voltage applied, plunger on end of VVT OCV should extend. Disconnect a jumper wire. Without battery voltage applied, plunger should retract. If VVT OCV operates as specified, go to next step. If VVT OCV does not operate as specified, replace VVT OCV and go to next step. 7. Check blockage in VVT OCV. Check oil check valve and oil pipe located under VVT OCV. If problem exists, repair as necessary. If problem does not exist, go to next step. 8. Install remove components all and connect all disconnected harness connectors. Using scan tool, clear DTCs. Start engine and allow it to idle. Turn ignition off. Turn ignition on and check for DTCs. If DTC P1349 is not present, no problem is indicated at this time. DTC may have been set because of a foreign object that was temporarily caught in the engine oil system but after a short time system returned to normal. If DTC P1349 is present, replace ECM. DTC P1520: STOPLIGHT SWITCH SIGNAL CIRCUIT (A/T ONLY) CAUTION: If ECM replacement is instructed in following testing, always ensure ECM connectors and ground circuits are okay. If either are suspect, repair and repeat testing to confirm ECM malfunction. NOTE: For component location, see appropriate illustration in THEORY & OPERATION article.

Circuit Description

Stoplight switch signal is used to detect when brakes have been applied. ECM uses this signal to control fuel cut-off engine speed. DTC is set if stoplight switch does not turn off when vehicle is being driven. Possible causes are:

Stoplight switch signal circuit is shorted. Defective stoplight switch. Defective ECM.

Diagnostic Aids

Using scan tool, read FREEZE FRAME data. Freeze frame data records engine conditions when malfunction is detected.
Diagnosis & Repair

1. Check stoplight operation. If stoplights do not operate properly, repair as necessary and retest system. See EXTERIOR LIGHTS article in ACCESSORIES & EQUIPMENT. If stoplights operate properly, go to next step. 2. Access ECM below stereo, behind instrument panel, just in front of center console. See Fig. 2 . Turn ignition on. Using DVOM, backprobe ECM harness connector and measure voltage between ground and terminal No. 6 (Green/White wire) at ECM harness connector E9. See Fig. 5 . With brake pedal

2002 ENGINE PERFORMANCE Self-Diagnostics - Corolla

depressed voltage should be 7.5-14.0 volts. With brake pedal released, voltage should be less than 1.5 volts. If voltage is not as specified, go to next step. If voltage is as specified, problem is intermittent. Check wiring and connectors. 3. Check for short in wiring between ECM and stoplight switch. If problem exists, repair wiring as necessary. If problem does not exist, replace ECM. DTC P1600: ECM BATT CIRCUIT CAUTION: If ECM replacement is instructed in following testing, always ensure ECM connectors and ground circuits are okay. If either are suspect, repair and repeat testing to confirm ECM malfunction. NOTE: For component location, see appropriate illustration in THEORY & OPERATION article.

Circuit Description

Battery voltage is supplied to ECM BATT terminal (constant). DTC is set when open in back-up power source is detected. Possible causes are:

Back-up power source circuit is open. Defective ECM.

Diagnostic Aids

If DTC P1600 exists, ECM will not store any other DTCs. Using scan tool, read FREEZE FRAME data. Freeze frame data records engine conditions when malfunction is detected.
Diagnosis & Repair

1. Turn ignition off. Access ECM below stereo, behind instrument panel, just in front of center console. See Fig. 2 . Using DVOM, backprobe ECM harness connector. On models with 3-speed A/T and M/T, measure voltage between ground and terminal No. 1 (Red/White wire) at ECM harness connector E6. See Fig. 4 . On models with 4-speed A/T transmission, measure voltage between ground and terminal No. 1 (Red/White wire) at ECM harness connector E10. See Fig. 5 . On all models, voltage should be 9-14 volts. If voltage is as specified, replace ECM. If voltage is not as specified, go to next step. NOTE: EFI fuse may also be referred to as F-HTR fuse.

2. Remove and inspect EFI fuse (15-amp). EFI fuse is located in engine room junction box. Replace fuse as necessary. If fuse is okay, check circuit between EFI fuse and ECM. See WIRING DIAGRAMS article. Repair wiring as necessary. DTC P1656: OIL CONTROL VALVE MALFUNCTION CAUTION: If ECM replacement is instructed in following testing, always ensure ECM connectors and ground circuits are okay. If either are suspect, repair and repeat testing to confirm ECM malfunction.

2002 ENGINE PERFORMANCE Self-Diagnostics - Corolla

NOTE:

Variable Valve Timing (VVT) sensor may also be referred to as camshaft position sensor.

Circuit Description

The Variable Valve Timing (VVT) system controls intake valve timing in response to driving conditions. Engine Control Module (ECM) controls Oil Control Valve (OCV) to ensure correct valve timing. A OCV is located in cylinder head at timing belt side of engine. Oil pressure controlled by the OCV is supplied to the VVT controller. VVT controller then changes relative position between camshaft and crankshaft. VVT controller is located on the front of intake camshaft. DTC P1656 is set if ECM detects an open or short in OCV circuit. Possible causes are:

OCV circuit is open or shorted. Defective OCV. Defective ECM.

Diagnostic Aids

Using scan tool, read FREEZE FRAME data. Freeze frame data records engine conditions when malfunction is detected.
Diagnosis & Repair (Using Toyota Hand-Held Tester)

1. Connect hand-held tester to Data Link Connector (DLC) No. 3. See Fig. 1 . Using hand-held tester, select ACTIVE TEST mode. Select VVT. Note idle speed when OCV is activated by hand-held tester. If idle speed is normal with OCV off, and engine idles rough or stalls when OCV is on, VVT is functioning properly at this time. DTC may have been set because of a foreign object that was temporarily caught in the engine oil system but after a short time system returned to normal. If idle speed does not function as specified, go to next step. 2. Start engine and allow it to idle. Disconnect Oil Control Valve (OCV) harness connector and note idle speed. Engine idle speed should not change. Using jumper wires, apply battery voltage and ground to OCV terminals. Engine should idle rough or stall. If OCV operates as specified, go to next step. If OCV does not operate as specified, replace OCV. 3. Access ECM below stereo, behind instrument panel, just in front of center console. See Fig. 2 . Using oscilloscope, backprobe ECM harness connector. On models with 3-speed A/T and M/T, connect oscilloscope between terminals No. 1 (Red wire) and No. 2 (Black wire) at ECM harness connector E4. See Fig. 4 . On models with 4-speed A/T transmission, connect oscilloscope between terminals No. 23 (Red wire) and No. 24 (Black wire) at ECM harness connector E7. See Fig. 5 . On all models, start engine and let idle. Ensure oscilloscope pattern is as shown in illustration. See Fig. 16 . As engine speed is increased, waveform frequency ("A") should lengthen. If waveform pattern is as shown, go to next step. If waveform pattern is not as shown, replace ECM. 4. Check for an open or short in wiring between OCV and ECM. If problem exists, repair wiring as necessary. If problem does not exist, problem is intermittent. Check component and ECM connections.
Diagnosis & Repair (Using OBD-II Scan Tool)

1. Start engine and allow it to idle. Disconnect Oil Control Valve (OCV) harness connector and note idle speed. OCV is located in each cylinder head, underneath lower intake manifold. Engine idle speed should not change. Using jumper wires, apply battery voltage and ground to OCV. Engine should idle

2002 ENGINE PERFORMANCE Self-Diagnostics - Corolla

rough or stall. If OCV operates as specified, go to next step. If OCV does not operate as specified, replace OCV. 2. Access ECM below stereo, behind instrument panel, just in front of center console. See Fig. 2 . Using oscilloscope, backprobe ECM harness connector. On models with 3-speed A/T and M/T, connect oscilloscope between terminals No. 1 (Red wire) and No. 2 (Black wire) at ECM harness connector E4. See Fig. 4 . On models with 4-speed A/T transmission, connect oscilloscope between terminals No. 23 (Red wire) and No. 24 (Black wire) at ECM harness connector E7. See Fig. 5 . On all models, start engine and let idle. Ensure oscilloscope pattern is as shown in illustration. See Fig. 16 . As engine speed is increased, waveform frequency ("A") should lengthen. If waveform pattern is as shown, go to next step. If waveform pattern is not as shown, replace ECM. 3. Check for an open or short in wiring between OCV and ECM. If problem exists, repair wiring as necessary. If problem does not exist, problem is intermittent. Check component and ECM connections. DTC P1780: PARK/NEUTRAL POSITION SWITCH CIRCUIT (A/T ONLY) CAUTION: If ECM replacement is instructed in following testing, always ensure ECM connectors and ground circuits are okay. If either are suspect, repair and repeat testing to confirm ECM malfunction. NOTE: For component location, see appropriate illustration in THEORY & OPERATION article.

Circuit Description

Park/Neutral Position (PNP) switch sends a signal to ECM when transaxle is in Neutral or Park. This signal is used for air/fuel correction and for idle speed control. DTC is set when 2 or more switches are on simultaneously for "R", "N", "2" and "L" position or when ECM is receiving an ON signal from PNP switch when vehicle is being operated for more than 30 seconds at 50 MPH or more (2000-5000 RPM). Possible causes are:

PNP switch circuit is shorted. Defective PNP switch. Defective ECM.

Diagnostic Aids

Using scan tool, read FREEZE FRAME data. Freeze frame data records engine conditions when malfunction is detected.
Diagnosis & Repair

NOTE:

Toyota hand-held tester can be used to confirm PNP switch signal from CURRENT DATA.

1. Access ECM below stereo, behind instrument panel, just in front of center console. See Fig. 2 . Turn ignition on. Using DVOM, backprobe and measure voltage between ground and specified terminal at ECM harness connector E9. See PARK/NEUTRAL POSITION SWITCH VOLTAGE table. See Fig. 5 . If voltage is as specified, no problem is indicated at this time. If voltage is not as specified, go

2002 ENGINE PERFORMANCE Self-Diagnostics - Corolla

to next step. PARK/NEUTRAL POSITION SWITCH VOLTAGE Shift Lever Position Park & Neutral 3 12 13 Reverse 3 12 13 Drive 2 3 12 13 2
(1) Terminal No.

Volts Zero Zero Zero Zero

(2) 9-14

Zero Zero
(2) 9-14

Zero Zero Zero 9-14 2 2 Zero 3 9-14 12 Zero 13 9-14 Low 2 Zero 3 Zero 12 9-14 13 9-14 (1) Measure voltage between ground and terminal listed, at ECM harness connector E9. See Fig. 5 . (2) Voltage may be slightly less due to lighting of reverse lights. 2. Disconnect PNP switch harness connector. Check continuity between appropriate PNP switch terminals (component side) with shift lever in appropriate position. See PARK/NEUTRAL POSITION SWITCH CONTINUITY table. See Fig. 18 . If problem exists, replace PNP switch. If problem does not exist, go to next step. PARK/NEUTRAL POSITION SWITCH CONTINUITY Continuity Between Shift Lever Position Terminals No. Park 1 & 3; 6 & 9 Reverse 2&3 Neutral 3 & 5; 6 & 9 Drive 3&7 2 3&4 Low 3&8 3. Check wiring between battery and PNP switch. Check wiring between PNP switch and ECM. See

2002 ENGINE PERFORMANCE Self-Diagnostics - Corolla

WIRING DIAGRAMS article. If problem exists, repair wiring as necessary. If problem does not exist, replace ECM.

Fig. 18: Identifying Park/Neutral Position Switch Terminals (Component Side) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 ENGINE PERFORMANCE System & Component Testing - 4-Cylinder

2002 ENGINE PERFORMANCE System & Component Testing - 4-Cylinder

INTRODUCTION
NOTE: Before performing system and component testing procedures, check for any related Technical Service Bulletins (TSBs). WARNING: On Prius, read service precautions before proceeding with service procedure. See SERVICE PRECAUTIONS . NOTE: References to California models apply to California emission vehicles, which may be verified by underhood Emission Control label. California emissions may be available in other states.

Before testing separate components or systems, follow proper workflow. See TESTING PROCEDURE under SELF-DIAGNOSTIC SYSTEM in appropriate SELF-DIAGNOSTICS article. If no Diagnostic Trouble Codes (DTC) are present and a no start condition exists, proceed to appropriate BASIC DIAGNOSTIC PROCEDURES article. If no DTCs are present and a driveability condition exists, proceed to TROUBLE SHOOTING - NO CODES article for diagnosis by symptom (i.e., ROUGH IDLE, NO START, etc.). NOTE: Testing individual components does not isolate shorts or opens. Perform all voltage tests with a Digital Volt-Ohmmeter (DVOM) with a minimum 10megohm input impedance, unless stated otherwise in test procedure. Use ohmmeter to isolate wiring harness shorts or opens.

SERVICE PRECAUTIONS
PRIUS WARNING: When performing any inspection or service procedure on this vehicle, ensure following service precautions are followed to prevent personal injury or death due to the extremely high voltage. The following service precautions must be followed:

Ensure ignition is off and ignition key is removed from ignition before performing any inspection or service procedure in engine compartment, as engine may automatically start and shut off when ignition is on and READY light is illuminated. READY light is displayed just above the shift lever position indicator on instrument cluster at center of instrument panel. Read all service and warning labels in engine compartment before performing any procedures in engine compartment. All high-voltage wiring harness connectors contain Orange connectors. DO NOT touch any wiring harness that contains Orange connectors. High-voltage battery and other high-voltage components may be identified by HIGH VOLTAGE

2002 ENGINE PERFORMANCE System & Component Testing - 4-Cylinder

caution labels on them. DO NOT touch these components. If necessary to inspect or service high-voltage system, ensure ignition is off. Remove service plug and wait at least 5 minutes to ensure high voltage is fully discharged before touching any high-voltage wiring harness, connectors or components. Service plug is located on service plug assembly at driver's side front corner of trunk compartment, near high-voltage battery. See Fig. 1 . Ensure service plug is stored in a location in which no one may install service plug while technician is working on the vehicle. If necessary to touch any high-voltage wiring harness, connectors or components, ensure service plug is removed and battery voltage or less exists at electrical connector. Use Toyota insulated gloves when touching any high-voltage wiring harness, connectors or components. Ensure insulated gloves are dry and in good condition and that no holes exist in insulated gloves by applying air to insulated glove before touching any high-voltage wiring harness, connectors or components. DO NOT wear any metal objects while working on vehicle which may accidently drop and cause a short circuit. If any high-voltage wiring harness connector is disconnected, ensure terminal on wiring harness connector is wrapped with tape to prevent wiring harness connector from contacting any surface. If servicing high-voltage system, place sign on roof of vehicle to indicate to other technicians that high-voltage system is being serviced.

2002 ENGINE PERFORMANCE System & Component Testing - 4-Cylinder

Fig. 1: Locating Service Plug & Service Plug Assembly (Prius) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

PROGRAMMING
POWER SUN ROOF REINITIALIZATION PROCEDURE

2002 ENGINE PERFORMANCE System & Component Testing - 4-Cylinder

Camry

NOTE:

Following procedure should be performed if battery is disconnected and reconnected, or battery is discharged and recharged to provide proper automatic operation and jam protection operation of power sun roof.

1. Ensure ignition is on. Depress and hold TILT UP side of power sun roof switch until power sun roof tilts all the way upward and then tilts downward a little. Power sun roof switch is located on headliner, just in front of power sun roof. 2. Check proper operation of open/closing and tilt up/down function for power sun roof using power sun roof switch. Power sun roof should operate anytime ignition is on, or for 43 seconds after ignition is off provided both front doors are closed. It will stop operating if any front door is opened. Depressing SLIDE OPEN side of power sun roof switch for one second should open power sun roof. Depressing TILT UP side of power sun roof switch for one second should close power sun roof. To tilt power sun roof upward, depress and hold TILT UP side of power sun roof switch for one second. To tilt power sun roof downward, depress and hold SLIDE OPEN side of power sun roof switch for one second.
Celica

NOTE:

Following procedure should be performed if battery is disconnected and reconnected, or battery is discharged and recharged to provide proper automatic operation and jam protection operation of power sun roof.

Close power sun roof using power sun roof switch and continue to depress power sun roof switch briefly after power sun roof is fully closed. Power sun roof switch is located on headliner, just in front of power sun roof.

AIR INDUCTION SYSTEMS

ACOUSTIC CONTROL INDUCTION SYSTEM VACUUM SWITCHING VALVE
Celica

NOTE:

Acoustic Control Induction System (ACIS) Vacuum Switching Valve (VSV) may also be referred to as intake air control valve system VSV.

1. Remove necessary components for access to ACIS VSV. ACIS VSV is located on bottom of air cleaner case. See Fig. 2 . 2. Remove ACIS VSV. Using ohmmeter, ensure continuity exists between electrical terminals on ACIS VSV and that resistance is 37-44 ohms at 68F (20C). Replace ACIS VSV if no continuity exists or resistance is not within specification. 3. Using ohmmeter, ensure no continuity exists between each electrical terminal and body of ACIS VSV. Replace ACIS VSV if continuity exists between electrical terminal and body of ACIS VSV. 4. To test ACIS VSV operation, apply air pressure to port "E". Ensure air flows from port "G". Perform STEP 1 in illustration. See Fig. 3 . 5. Apply battery voltage and ground to electrical terminals on ACIS VSV. Apply air pressure to port "E". Ensure air flows from port "F" and not from port "G". Perform STEP 2 in illustration. See Fig. 3 . Replace ACIS VSV if defective. Reinstall ACIS VSV.

2002 ENGINE PERFORMANCE System & Component Testing - 4-Cylinder

Fig. 3: Testing Acoustic Control Induction System Vacuum Switching Valve (Celica) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ELECTRONIC THROTTLE CONTROL SYSTEM NOTE: Electronic Throttle Control System (ETCS) may also be referred to as Electronic Throttle Control System-Intelligent (ETCS-I or ETCS-i).

Camry, Camry Solara, MR2 With Sequential Manual Transaxle & Prius

For testing of throttle body and components, see THROTTLE BODY under IDLE CONTROL SYSTEMS.

COMPUTERIZED ENGINE CONTROLS

A/C COMPRESSOR LOCK SENSOR CIRCUIT
Camry, Celica & Highlander

2002 ENGINE PERFORMANCE System & Component Testing - 4-Cylinder

Testing information is not available from manufacturer.

Camry Solara With Manual A/C & MR2

CAUTION: If Engine Control Module (ECM) replacement is instructed in the following testing, always ensure ECM wiring harness electrical connector and ground circuit are okay. If either are defective, repair and repeat testing to confirm ECM malfunction. 1. Check A/C compressor drive belt for proper tension. If A/C compressor drive belt has proper belt tension, go to next step. If A/C compressor drive belt does not have proper belt tension, it may be necessary to replace automatic belt tensioner and then go to next step. 2. Start engine and note if A/C compressor locks when blower and A/C switches are in ON position. If A/C compressor does not lock, go to next step. If A/C compressor locks, repair A/C compressor as necessary. 3. Check A/C compressor lock sensor. See A/C COMPRESSOR LOCK SENSOR under ENGINE SENSORS & SWITCHES. If A/C compressor lock sensor is okay, go to next step. If A/C compressor lock sensor is defective, replace A/C compressor lock sensor. 4. On Camry Solar, remove glove box for access to Engine Control Module (ECM). For illustration of ECM location, see THEORY & OPERATION article. On MR2, remove luggage compartment lids, luggage compartment boxes and quarter trim panels for access to Engine Control Module (ECM). ECM is located on inside of firewall, directly behind driver's seat and luggage compartment. For illustration of ECM location, see THEORY & OPERATION article. For additional information on removal of luggage compartment components, see FUEL PUMP under FUEL SYSTEMS in REMOVAL, OVERHAUL & INSTALLATION - 4-CYLINDER article. 5. On all models, note ECM electrical connector terminals. See Fig. 19 and Fig. 25 . Connect oscilloscope between proper terminals on ECM for A/C compressor lock sensor. See ECM TERMINAL IDENTIFICATION & CIRCUIT IDENTIFICATION FOR A/C COMPRESSOR LOCK SENSOR table. These are the LCK1 and E1 terminals at ECM. ECM TERMINAL IDENTIFICATION & CIRCUIT IDENTIFICATION FOR A/C COMPRESSOR LOCK SENSOR ECM ECM Terminal No. (Wire Connector Color) Application (1) 23 (White/Blue) Camry Solara E9 E9 MR2 E4 ECM. (2) This is the ground circuit at ECM. 6. Check A/C compressor lock sensor wave pattern on oscilloscope during cranking or with engine idling. A/C compressor lock sensor wave pattern should switch from between zero volts and .2 volts within 20 milliseconds. See Fig. 4 . If A/C compressor lock sensor wave pattern is as specified, go to next step. If A/C compressor lock sensor wave pattern is not at specified, replace A/C compressor lock sensor. E3
(2) 1 (Brown) (1) 28 (White/Red) (2) 17 (Brown)

(1) This is the A/C compressor lock sensor signal circuit at

2002 ENGINE PERFORMANCE System & Component Testing - 4-Cylinder

7. On Camry Solara, go to next step. On MR2, check A/C compressor clutch relay. See A/C COMPRESSOR CLUTCH RELAY under MODULES, MOTORS, RELAYS & SOLENOIDS. If A/C compressor clutch relay is okay, go to next step. If A/C compressor clutch relay is defective, replace A/C compressor clutch relay. 8. On all models, check wiring harness and electrical connectors for A/C compressor lock sensor between ECM and A/C compressor lock sensor for any problems. See ECM TERMINAL IDENTIFICATION & CIRCUIT IDENTIFICATION FOR A/C COMPRESSOR LOCK SENSOR table. If wiring harness or electrical connector is defective, repair as necessary. If wiring harness and electrical connectors are okay, check ECM ground circuit. See WIRING DIAGRAMS article. If ECM ground circuit is defective, repair ground circuit as necessary. If ECM ground circuit is okay, replace ECM. If ECM is replaced and vehicle is equipped with engine immobilizer system, ECM must be programmed with proper ignition key code for engine immobilizer system. Models equipped with engine immobilizer system may be identified by looking at the ignition key. On models equipped with engine immobilizer system, the top of the ignition key is thicker than a standard ignition key, as a transponder chip is incorporated into the top of the ignition key. For programming procedures, see COMPUTER RELEARN PROCEDURES article in GENERAL INFORMATION, or appropriate ENGINE IMMOBILIZER SYSTEMS article in ACCESSORIES & EQUIPMENT.

2002 ENGINE PERFORMANCE System & Component Testing - 4-Cylinder

Fig. 4: Identifying A/C Compressor Lock Sensor Wave Pattern (Camry Solara With Manual A/C & MR2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
RAV4

CAUTION: If Engine Control Module (ECM) replacement is instructed in the following testing, always ensure ECM wiring harness electrical connector and ground circuit are okay. If either are defective, repair and repeat testing to confirm ECM malfunction. 1. Remove glove box for access to Engine Control Module (ECM). ECM is located near passenger's side kick panel, just below instrument panel. For illustration of ECM location, see THEORY & OPERATION article. Note terminals on ECM electrical connector. See Fig. 27 . 2. Turn ignition on. Using voltmeter, check voltage between body ground and terminal No. 15

2002 ENGINE PERFORMANCE System & Component Testing - 4-Cylinder

3.

4.

5.

6.

(Red/Yellow or White wire) at ECM electrical connector E7. This is the ACMG terminal on ECM. There are 2 different wiring harnesses used. Wire color at designated terminal may vary according to wiring harness used. Voltage should be 9-14 volts. If voltage is within specification, go to next step. If voltage is not within specification, check Red/Yellow or White wire and electrical connector between ECM and terminal No. 3 (Red/Yellow or White wire) at electrical connector 3S on passenger's side junction block Electronic Control Unit (ECU). See Fig. 5 . Check A/C compressor drive belt for proper tension. If A/C compressor drive belt has proper belt tension, go to next step. If A/C compressor drive belt does not have proper belt tension, it may be necessary to replace automatic belt tensioner and then go to next step. Start engine and note if A/C compressor locks when blower and A/C switches are in ON position. If A/C compressor does not lock, go to next step. If A/C compressor locks, repair A/C compressor as necessary. Check A/C compressor lock sensor. See A/C COMPRESSOR LOCK SENSOR under ENGINE SENSORS & SWITCHES. If A/C compressor lock sensor is okay, go to next step. If A/C compressor lock sensor is defective, replace A/C compressor lock sensor. Check wiring harness and electrical connectors between A/C compressor lock sensor, passenger's side junction block ECU, A/C amplifier and ECM. See WIRING DIAGRAMS in appropriate article in AIR CONDITIONING & HEATING. A/C amplifier is located behind center of instrument panel. See Fig. 5 . If wiring harness or electrical connector is defective, repair as necessary. If wiring harness and electrical connectors are okay, check ECM ground circuit. See WIRING DIAGRAMS article. If ECM ground circuit is defective, repair ground circuit as necessary. If ECM ground circuit is okay, replace ECM. On models equipped with engine immobilizer system, if ECM is replaced, ECM must be programmed with proper ignition key code for engine immobilizer system. Models equipped with engine immobilizer system may be identified by looking at the ignition key. On models equipped with engine immobilizer system, the top of the ignition key is thicker than a standard ignition key, as a transponder chip is incorporated into the top of the ignition key. For programming procedures, see COMPUTER RELEARN PROCEDURES article in GENERAL INFORMATION, or appropriate ENGINE IMMOBILIZER SYSTEMS article in ACCESSORIES & EQUIPMENT.

2002 ENGINE PERFORMANCE System & Component Testing - 4-Cylinder

Fig. 5: Locating Passenger's Side Junction Block Electronic Control Unit, A/C Amplifier & Identifying Electrical Connectors (RAV4) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. A/C-CUT CONTROL SYSTEM CIRCUIT
Highlander, MR2 & RAV4

Testing information is not available from manufacturer.

Corolla

1. If Toyota hand-held tester is available, go to next step. If Toyota hand-held tester is not available, go

2002 ENGINE PERFORMANCE System & Component Testing - 4-Cylinder

2.

3.

4.

5.

6. 7.

8.

9.

to step 10 . Connect hand-held tester to data link connector No. 3 at driver's side of instrument panel. See Fig. 11 . Turn ignition on and then turn hand-held tester on. Start engine and turn A/C switch to ON position. Ensure A/C clutch engages. Select ACTIVE TEST MODE on hand-held tester. Check operation of A/C clutch when A/C-cut control is operated by hand-held tester. A/C clutch should turn off (stop operating) when A/C-cut control is operated by hand-held tester. If A/C clutch does not operate properly, go to next step. If A/C clutch operates properly, shut engine off. Remove hand-held tester. Diagnose by symptom. See TROUBLE SHOOTING - NO CODES article. Check for open and short in wiring harness and electrical connectors between Engine Control Module (ECM) and A/C amplifier. See WIRING DIAGRAMS in appropriate article in AIR CONDITIONING & HEATING. ECM is located behind stereo on instrument panel, just in front of center console. For illustration of ECM location, see THEORY & OPERATION article. A/C amplifier is located behind instrument panel, just above glove box, near center of glove box area. See Fig. 6 . If wiring harness and electrical connectors are okay, go to next step. If wiring harness or electrical connector is defective, repair as necessary. Remove necessary components for access to ECM. See ENGINE CONTROL MODULE under COMPUTERIZED ENGINE CONTROLS in REMOVAL, OVERHAUL & INSTALLATION - 4CYLINDER article. Remove bolts from ECM so electrical connectors can be accessed. Note ECM electrical connector terminals. See Fig. 21 and Fig. 22 . Start engine. On 3-speed A/T and M/T models, using voltmeter, check voltage between body ground and terminal No. 21 (Red/Blue wire) at ECM electrical connector E6 while turning A/C switch from ON to OFF positions. See Fig. 21 . This is the ACT terminal at ECM. On 4-speed A/T models, using voltmeter, check voltage between body ground and terminal No. 12 (Red/Blue wire) at ECM electrical connector E10 while turning A/C switch from ON to OFF positions. See Fig. 22 . This is the ACT terminal at ECM. On all models, voltage should be 9-14 volts with A/C switch in ON position and less than 1.5 volts with A/C switch in OFF position. If voltage is as specified, go to next step. If voltage is not as specified, check for open and short in wiring harness and electrical connectors between ECM and A/C amplifier. See WIRING DIAGRAMS in appropriate article in AIR CONDITIONING & HEATING. A/C amplifier is located behind instrument panel, just above glove box, near center of glove box area. See Fig. 6 . If wiring harness and electrical connectors are okay, replace A/C amplifier. If wiring harness or electrical connector is defective, repair as necessary. Check ECM ground circuit. See WIRING DIAGRAMS article. If ECM ground circuit is defective, repair ground circuit as necessary. If ECM ground circuit is okay, replace ECM.

2002 ENGINE PERFORMANCE System & Component Testing - 4-Cylinder

Fig. 6: Locating A/C Amplifier (Corolla) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 10. Remove necessary components for access to Engine Control Module (ECM). See ENGINE CONTROL MODULE under COMPUTERIZED ENGINE CONTROLS in REMOVAL, OVERHAUL & INSTALLATION - 4-CYLINDER article. 11. Remove bolts from ECM so electrical connectors can be accessed on ECM. Note ECM electrical connector terminals. See Fig. 21 and Fig. 22 . 12. Start engine. On 3-speed A/T and M/T models, using voltmeter, check voltage between body ground and terminal No. 21 (Red/Blue wire) at ECM electrical connector E6 while turning A/C switch from ON to OFF positions. This is the ACT terminal at ECM. On 4-speed A/T models, using voltmeter, check voltage between body ground and terminal No. 12 (Red/Blue wire) at ECM electrical connector E10 while turning A/C switch from ON to OFF positions. This is the ACT terminal at ECM. 13. On all models, voltage should be 9-14 volts with A/C switch in ON position and less than 1.5 volts with A/C switch in OFF position. If voltage is not as specified, go to next step. If voltage is as specified, check ECM ground circuit. See WIRING DIAGRAMS article. If ECM ground circuit is defective, repair ground circuit as necessary. If ECM ground circuit is okay, replace ECM. 14. Check for open and short in wiring harness and electrical connectors between ECM and A/C amplifier. See WIRING DIAGRAMS in appropriate article in AIR CONDITIONING & HEATING. A/C amplifier is located behind instrument panel, just above glove box, near center of glove box area. See Fig. 6 . If wiring harness and electrical connectors are okay, replace A/C amplifier. If wiring harness or electrical connector is defective, repair as necessary.
Prius

2002 ENGINE PERFORMANCE System & Component Testing - 4-Cylinder

WARNING: Read service precautions before proceeding with service procedure. See SERVICE PRECAUTIONS . 1. If Toyota hand-held tester is available, go to next step. If Toyota hand-held tester is not available, go to step 7 . 2. Connect hand-held tester to data link connector No. 3 at driver's side of instrument panel. See Fig. 15 . Turn ignition on and then turn hand-held tester on. Start engine and turn A/C switch to ON position. Ensure A/C clutch engages. 3. Select ACTIVE TEST MODE on hand-held tester. Check operation of A/C clutch when A/C-cut control is operated by hand-held tester. A/C clutch should turn off (stop operating) when A/C-cut control is operated by hand-held tester. If A/C clutch does not operate properly, go to next step. If A/C clutch operates properly, shut engine off. Remove hand-held tester. Diagnose by symptom. See TROUBLE SHOOTING - NO CODES article. 4. Check for open and short in wiring harness and electrical connectors between Engine Control Module (ECM) and A/C amplifier. See WIRING DIAGRAMS in appropriate article in AIR CONDITIONING & HEATING. ECM is located behind glove box. See Fig. 7 . A/C amplifier is attached to rear of center cluster module control. See Fig. 7 . If wiring harness and electrical connectors are okay, go to next step. If wiring harness or electrical connector is defective, repair as necessary.

2002 ENGINE PERFORMANCE System & Component Testing - 4-Cylinder

Fig. 7: Locating Engine Control Module & A/C Amplifier (Prius) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 5. Remove ECM with electrical connectors still attached. See ENGINE CONTROL MODULE under COMPUTERIZED ENGINE CONTROLS in REMOVAL, OVERHAUL & INSTALLATION - 4CYLINDER article. 6. Note ECM electrical connector terminals. See Fig. 26 . Start engine. Using voltmeter, check voltage between body ground and terminal No. 22 (Pink/Green wire) at ECM electrical connector E10 while turning A/C switch from ON to OFF positions. This is the ACT terminal at ECM. Voltage should be 9-14 volts with A/C switch in ON position and less than 1.5 volts with A/C switch in OFF position. If voltage is not as specified, replace A/C amplifier. If voltage is as specified, check ECM ground circuit. See WIRING DIAGRAMS article. If ECM ground circuit is defective, repair ground circuit as necessary. If ECM ground circuit is okay, replace ECM. 7. Remove ECM with electrical connectors still attached. ECM is located behind glove box. See Fig. 7 . See ENGINE CONTROL MODULE under COMPUTERIZED ENGINE CONTROLS in REMOVAL, OVERHAUL & INSTALLATION - 4-CYLINDER article.

2002 ENGINE PERFORMANCE System & Component Testing - 4-Cylinder

8. Note ECM electrical connector terminals. See Fig. 26 . Start engine. Using voltmeter, check voltage between body ground and terminal No. 22 (Pink/Green wire) at ECM electrical connector E10 while turning A/C switch from ON to OFF positions. This is the ACT terminal at ECM. Voltage should be 9-14 volts with A/C switch in ON position and less than 1.5 volts with A/C switch in OFF position. If voltage is not as specified, go to next step. If voltage is as specified, check ECM ground circuit. See WIRING DIAGRAMS article. If ECM ground circuit is defective, repair ground circuit as necessary. If ECM ground circuit is okay, replace ECM. 9. Check for open and short in wiring harness and electrical connectors between ECM and A/C amplifier. See WIRING DIAGRAMS in appropriate article in AIR CONDITIONING & HEATING. A/C amplifier is attached to rear of center cluster module control. See Fig. 7 . If wiring harness and electrical connectors are okay, replace A/C amplifier. If wiring harness or electrical connector is defective, repair as necessary. A/C EVAPORATOR TEMPERATURE SENSOR CIRCUIT
Camry

Testing information is not available from manufacturer.

Camry Solara With Manual A/C

CAUTION: If Engine Control Module (ECM) replacement is instructed in the following testing, always ensure ECM wiring harness electrical connector and ground circuit are okay. If either are defective, repair and repeat testing to confirm ECM malfunction. 1. Remove glove box for access to Engine Control Module (ECM). For illustration of ECM location, see THEORY & OPERATION article. Note ECM electrical connector terminals. See Fig. 19 . 2. Turn ignition on. Using voltmeter, check voltage between terminal No. 32 (Blue/White wire) at ECM electrical connector E8 and terminal No. 28 (Brown wire) at ECM electrical connector E11. This is the THR and E2 terminals at ECM. Voltage should be 2.2-2.6 volts at 32F (0C) and 1.4-1.8 volts at 59F (15C). If voltage is not within specification, go to next step. If voltage is within specification, check ECM ground circuit. See WIRING DIAGRAMS article. If ECM ground circuit is defective, repair ground circuit as necessary. If ECM ground circuit is okay, replace ECM. If ECM is replaced and vehicle is equipped with engine immobilizer system, ECM must be programmed with proper ignition key code for engine immobilizer system. Models equipped with engine immobilizer system may be identified by looking at the ignition key. On models equipped with engine immobilizer system, the top of the ignition key is thicker than a standard ignition key, as a transponder chip is incorporated into the top of the ignition key. For programming procedures, see COMPUTER RELEARN PROCEDURES article in GENERAL INFORMATION, or appropriate ENGINE IMMOBILIZER SYSTEMS article in ACCESSORIES & EQUIPMENT. 3. Check A/C evaporator temperature sensor operation. See A/C EVAPORATOR TEMPERATURE SENSOR under ENGINE SENSORS & SWITCHES. If A/C evaporator temperature sensor operates properly, go to next step. If A/C evaporator temperature sensor is defective, replace A/C evaporator temperature sensor. For servicing of A/C evaporator temperature sensor, see appropriate article in AIR CONDITIONING & HEATING. 4. Check wiring harness and electrical connectors between ECM and A/C evaporator temperature sensor. See WIRING DIAGRAMS article. It may be necessary to see appropriate MANUAL or AUTOMATIC A/C-HEATER SYSTEMS article in AIR CONDITIONING & HEATING for complete wiring diagram. If wiring harness or electrical connector is defective, repair as necessary. If

2002 ENGINE PERFORMANCE System & Component Testing - 4-Cylinder

wiring harness and electrical connectors are okay, check ECM ground circuit. See WIRING DIAGRAMS article. If ECM ground circuit is defective, repair ground circuit as necessary. If ECM ground circuit is okay, replace ECM. If ECM is replaced and vehicle is equipped with engine immobilizer system, ECM must be programmed with proper ignition key code for engine immobilizer system. Models equipped with engine immobilizer system may be identified by looking at the ignition key. On models equipped with engine immobilizer system, the top of the ignition key is thicker than a standard ignition key, as a transponder chip is incorporated into the top of the ignition key. For programming procedures, see COMPUTER RELEARN PROCEDURES article in GENERAL INFORMATION, or appropriate ENGINE IMMOBILIZER SYSTEMS article in ACCESSORIES & EQUIPMENT. ENGINE CONTROL MODULE POWER SOURCE CIRCUIT CAUTION: If Engine Control Module (ECM) replacement is instructed in the following testing, always ensure ECM wiring harness electrical connector and ground circuit are okay. If either are defective, repair and repeat testing to confirm ECM malfunction. NOTE: When performing test for Engine Control Module (ECM) power source circuit, it may be necessary to check wiring harness and components connected to a specified fuse, or check wiring harness and electrical connectors between EFI main relay and battery. For additional wiring information for fuse and power supply circuit, see POWER DISTRIBUTION article in WIRING DIAGRAMS.

Camry

1. Remove glove box for access to Engine Control Module (ECM). For illustration of ECM location, see THEORY & OPERATION article. Note ECM electrical connector terminals. See Fig. 18 . 2. Turn ignition on. Using voltmeter, check voltage between terminals No. 1 (Black/Red wire) at ECM electrical connector E6 and No. 1 (Brown wire) at ECM electrical connector E8. This is the +B and E1 terminals at ECM. Voltage should be 9-14 volts. If voltage is not within specification, go to next step. If voltage is within specification, diagnose by symptom. See TROUBLE SHOOTING - NO CODES article. 3. Turn ignition off. Disconnect electrical connector E8 from ECM. Using ohmmeter, check for continuity between body ground and terminal No. 1 (Brown wire) at ECM electrical connector E8. If continuity exists, reinstall electrical connector E8 at ECM and go to next step. If continuity does not exist, repair open in Brown wire between terminal No. 1 at ECM electrical connector E8 and body ground. See WIRING DIAGRAMS article. 4. Ensure ignition is off. Check for open and short in Black/Red wire between EFI main relay and terminal No. 1 at ECM electrical connector E6. See WIRING DIAGRAMS article. EFI main relay is located in fuse/relay box at driver's side front corner of engine compartment. If wiring is okay, go to next step. If wiring is defective, repair as necessary. 5. Turn ignition on. Using voltmeter, check voltage between terminals No. 9 (Black/Orange wire) at ECM electrical connector E6 and No. 1 (Brown wire) at ECM electrical connector E8. This is the IGSW and E1 terminals at ECM. Voltage should be 9-14 volts. If voltage is not within specification, go to next step. If voltage is within specification, go to step 9 . 6. Check for defective IG2 fuse. IG2 fuse is located in fuse/relay box at driver's side front corner of engine compartment. If IG2 fuse is okay, go to next step. If IG2 fuse is defective, repair short in

2002 ENGINE PERFORMANCE System & Component Testing - 4-Cylinder

7.

8.

9.

10.

11.

12.

13.

wiring harness and components connected to IG2 fuse. See WIRING DIAGRAMS article. Check for defective AM2 fuse. AM2 fuse is located in fuse/relay box at driver's side front corner of engine compartment. If AM2 fuse is okay, go to next step. If AM2 fuse is defective, repair short in wiring harness and components connected to AM2 fuse. See WIRING DIAGRAMS article. Check ignition switch. See IGNITION SWITCH under ENGINE SENSORS & SWITCHES. If ignition switch is okay, repair wiring harness or electrical connectors between ignition switch and terminal No. 9 (Black/Orange wire) at ECM electrical connector E6. See WIRING DIAGRAMS article. If ignition switch is defective, replace ignition switch. See IGNITION SWITCH under ENGINE SENSORS & SWITCHES in REMOVAL, OVERHAUL & INSTALLATION - 4CYLINDER article. Ensure ignition is on. Using voltmeter, check voltage between terminals No. 8 (Black/White wire) at ECM electrical connector E6 and No. 1 (Brown wire) at ECM electrical connector E8. This is the MREL and E1 terminals at ECM. Voltage should be 9-14 volts. If voltage is within specification, go to next step. If voltage is not within specification, check ECM ground circuit. See WIRING DIAGRAMS article. If ECM ground circuit is defective, repair ground circuit as necessary. If ECM ground circuit is okay, replace ECM. On models equipped with engine immobilizer system, if ECM is replaced, ECM must be programmed with proper ignition key code for engine immobilizer system. For programming procedures, see COMPUTER RELEARN PROCEDURES article in GENERAL INFORMATION, or appropriate ENGINE IMMOBILIZER SYSTEMS article in ACCESSORIES & EQUIPMENT. Check for defective EFI fuse. EFI fuse is located in fuse/relay box at driver's side front corner of engine compartment. If EFI fuse is okay, go to next step. If EFI fuse is defective, repair short in wiring harness and components connected to EFI fuse. See WIRING DIAGRAMS article. Check operation of EFI main relay. See EFI MAIN RELAY under MODULES, MOTORS, RELAYS & SOLENOIDS. If EFI main relay operates properly, go to next step. If EFI main relay is defective, replace EFI main relay. Check for open and short in wiring harness and electrical connectors between terminal No. 8 (Black/White wire) at ECM electrical connector E6 and EFI main relay, and for open in White/Black wire between EFI main relay and body ground. See WIRING DIAGRAMS article. If wiring harness and electrical connectors are okay, go to next step. If wiring harness or electrical connector is defective, repair as necessary. Check wiring harness and electrical connectors between battery and EFI fuse. See WIRING DIAGRAMS article. Repair wiring harness or and electrical connectors as necessary.

Camry Solara

1. Remove glove box for access to Engine Control Module (ECM). For illustration of ECM location, see THEORY & OPERATION article. Note ECM electrical connector terminals. See Fig. 19 . 2. Turn ignition on. Using voltmeter, check voltage between terminals No. 1 (Red wire) at ECM electrical connector E7 and No. 1 (Brown wire) at ECM electrical connector E9. This is the +B and E1 terminals at ECM. Voltage should be 9-14 volts. If voltage is not within specification, go to next step. If voltage is within specification, diagnose by symptom. See TROUBLE SHOOTING - NO CODES article. 3. Turn ignition off. Check for open in wiring harness and electrical connectors between body ground and terminal No. 1 (Brown wire) at ECM electrical connector E9. See WIRING DIAGRAMS article. If wiring harness and electrical connectors are okay, go to next step. If wiring harness or electrical connector is defective, repair as necessary. 4. Ensure ignition is off. Check for open and short in Red wire between EFI main relay and terminal No. 1 at ECM electrical connector E7. See WIRING DIAGRAMS article. EFI main relay is located in

2002 ENGINE PERFORMANCE System & Component Testing - 4-Cylinder

5.

6.

7.

8.

9.

10.

11.

12.

fuse/relay box at driver's side front corner of engine compartment. If wiring is okay, go to next step. If wiring is defective, repair as necessary. Turn ignition on. Using voltmeter, check voltage between body ground and terminal No. 9 (Black/Red wire) at ECM electrical connector E7. This is IGSW terminal at ECM. Voltage should be 9-14 volts. If voltage is not within specification, go to next step. If voltage is within specification, go to step 8 . Check for defective IGN fuse. IGN fuse is located in fuse box behind driver's side of instrument panel. If IGN fuse is okay, go to next step. If IGN fuse is defective, repair short in wiring harness and components connected to IGN fuse. See WIRING DIAGRAMS article. Check ignition switch. See IGNITION SWITCH under ENGINE SENSORS & SWITCHES. If ignition switch is defective, replace ignition switch. See IGNITION SWITCH under ENGINE SENSORS & SWITCHES in REMOVAL, OVERHAUL & INSTALLATION - 4-CYLINDER article. If ignition switch is okay, repair wiring harness or electrical connectors between battery and ignition switch, and between ignition switch and terminal No. 9 (Black/Red wire) at ECM electrical connector E7. See WIRING DIAGRAMS article. If necessary to check AM2 fuse, AM2 fuse is located in fuse/relay box at driver's side front corner of engine compartment. Ensure ignition is on. Using voltmeter, check voltage between body ground and terminal No. 8 (Black/Red wire) at ECM electrical connector E7. This is the MREL terminal at ECM. Voltage should be 9-14 volts. If voltage is within specification, go to next step. If voltage is not within specification, check ECM ground circuit. See WIRING DIAGRAMS article. If ECM ground circuit is defective, repair ground circuit as necessary. If ECM ground circuit is okay, replace ECM. On models equipped with engine immobilizer system, if ECM is replaced, ECM must be programmed with proper ignition key code for engine immobilizer system. For programming procedures, see COMPUTER RELEARN PROCEDURES article in GENERAL INFORMATION, or appropriate ENGINE IMMOBILIZER SYSTEMS article in ACCESSORIES & EQUIPMENT. Check for defective EFI fuse. EFI fuse is located in fuse/relay box at driver's side front corner of engine compartment. If EFI fuse is okay, go to next step. If EFI fuse is defective, repair short in wiring harness and components connected to EFI fuse. See WIRING DIAGRAMS article. Check operation of EFI main relay. See EFI MAIN RELAY under MODULES, MOTORS, RELAYS & SOLENOIDS. If EFI main relay operates properly, go to next step. If EFI main relay is defective, replace EFI main relay. Check for open and short in wiring harness and electrical connectors between terminal No. 8 (Black/Red wire) at ECM electrical connector E7 and EFI main relay, and for open in White/Black wire between EFI main relay and body ground. See WIRING DIAGRAMS article. If wiring harness and electrical connectors are okay, go to next step. If wiring harness or electrical connector is defective, repair as necessary. Check wiring harness and electrical connectors between battery and EFI fuse. See WIRING DIAGRAMS article. Repair wiring harness or and electrical connectors as necessary.

Celica

1. Remove cover for access to Engine Control Module (ECM). ECM is located in engine compartment, below cover, just in front of battery, next to driver's side strut tower. For illustration of ECM location, see THEORY & OPERATION article. Note ECM electrical connector terminals. See Fig. 20 . 2. Turn ignition on. Using voltmeter, check voltage between terminals No. 16 (Black/Red wire) at ECM electrical connector E2 and No. 17 (Brown wire) at ECM electrical connector E4. This is the +B and E1 terminals at ECM. Voltage should be 9-14 volts. If voltage is within specification, diagnose by symptom. See TROUBLE SHOOTING - NO CODES article. If voltage is not within specification, check for open in wiring harness and electrical connectors between terminal No. 17 (Brown wire) at ECM electrical connector E4 and body ground. See WIRING DIAGRAMS article. If wiring harness

2002 ENGINE PERFORMANCE System & Component Testing - 4-Cylinder

3.

4.

5.

6.

7.

8.

9.

and electrical connectors are okay, go to next step. If wiring harness or electrical connector is defective, repair as necessary. Ensure ignition is on. Using voltmeter, check voltage between body ground and terminal No. 8 (Black/Orange wire) at ECM electrical connector E2. This is the IGSW terminal at ECM. Voltage should be 9-14 volts. If voltage is not within specification, go to next step. If voltage is within specification, go to step 5 . Check ignition switch. See IGNITION SWITCH under ENGINE SENSORS & SWITCHES. If ignition switch is defective, replace ignition switch. See IGNITION SWITCH under ENGINE SENSORS & SWITCHES in REMOVAL, OVERHAUL & INSTALLATION - 4-CYLINDER article. If ignition switch is okay, check for open and short in wiring harness and electrical connectors between battery and ignition switch, and between ignition switch and terminal No. 8 (Black/Orange wire) at ECM electrical connector E2. See WIRING DIAGRAMS article. If necessary to check AM2 fuse, AM2 fuse is located in fuse/relay box at driver's side front corner of engine compartment, just in front of strut tower. Repair wiring harness or electrical connectors as necessary. Check operation of EFI main relay. See EFI MAIN RELAY under MODULES, MOTORS, RELAYS & SOLENOIDS. If EFI main relay operates properly, go to next step. If EFI main relay is defective, replace EFI main relay. Check for defective EFI fuse. EFI fuse is located in fuse/relay box at driver's side front corner of engine compartment, just in front of strut tower. If EFI fuse is okay, go to next step. If EFI fuse is defective, repair short in wiring harness between battery and EFI fuse. See WIRING DIAGRAMS article. Check for defective EFI No. 1 fuse. EFI No. 1 fuse is located in fuse/relay box at driver's side front corner of engine compartment, just in front of strut tower. EFI No. 1 fuse may also be referred to as EFI1 fuse. If EFI No. 1 fuse is okay, go to next step. If EFI No. 1 fuse is defective, repair short in wiring harness and components connected to EFI No. 1 fuse. See WIRING DIAGRAMS article. Check for open and short in wiring harness and electrical connectors between terminal No. 21 (Blue/Black wire) at ECM electrical connector E3 and EFI main relay, and for open in White/Black wire between EFI main relay and body ground. See WIRING DIAGRAMS article. If wiring harness and electrical connectors are okay, go to next step. If wiring harness or electrical connector is defective, repair as necessary. Check wiring harness and electrical connectors between battery and EFI fuse, and between EFI No. 1 fuse and terminal No. 16 (Black/Red wire) at ECM electrical connector E2. Repair wiring harness or and electrical connectors as necessary.

Corolla

1. Remove necessary components for access to Engine Control Module (ECM). See ENGINE CONTROL MODULE under COMPUTERIZED ENGINE CONTROLS in REMOVAL, OVERHAUL & INSTALLATION - 4-CYLINDER article. 2. Remove bolts from ECM so electrical connectors can be accessed on ECM. Note ECM electrical connector terminals. See Fig. 21 and Fig. 22 . 3. Turn ignition on. On 3-speed A/T and M/T models, using voltmeter, check voltage between terminals No. 12 (Black wire) at ECM electrical connector E6 and No. 14 (Brown wire) at ECM electrical connector E4. On 4-speed A/T, using voltmeter, check voltage between terminals No. 16 (Black wire) at ECM electrical connector E10 and No. 17 (Brown wire) at ECM electrical connector E8. On all models, this is the +B and E1 terminals at ECM. Voltage should be 9-14 volts. If voltage is within specification, diagnose by symptom. See TROUBLE SHOOTING - NO CODES article. If voltage is not within specification, check for open in wiring harness and electrical connectors between terminal No. 14 (Brown wire) at ECM electrical connector E4 and body ground on 3-speed A/T and

2002 ENGINE PERFORMANCE System & Component Testing - 4-Cylinder

4.

5.

6.

7.

8.

9.

M/T models, or terminal No. 17 (Brown wire) at ECM electrical connector E8 and body ground on 4speed A/T models. See WIRING DIAGRAMS article. On all models, if wiring harness and electrical connectors are okay, go to next step. If wiring harness or electrical connector is defective, repair as necessary. Check operation of EFI main relay. See EFI MAIN RELAY under MODULES, MOTORS, RELAYS & SOLENOIDS. EFI main relay may also be referred to as EFI relay or F-HTR relay. If EFI main relay operates properly, go to next step. If EFI main relay is defective, replace EFI main relay. Check for defective EFI fuse. EFI fuse may also be referred to as F-HTR fuse. EFI fuse is located in fuse/relay box at driver's side front corner of engine compartment, just in front of strut tower. If EFI fuse is okay, go to next step. If EFI fuse is defective, repair short in wiring harness and components connected to EFI fuse. See WIRING DIAGRAMS article. Check for open in wiring harness and electrical connectors between EFI main relay and battery, and between EFI main relay and ECM. See WIRING DIAGRAMS article. If wiring harness and electrical connectors are okay, go to next step. If wiring harness or electrical connector is defective, repair as necessary. Check for defective IGN fuse. IGN fuse is located in fuse/relay box behind driver's side of instrument panel. If IGN fuse is okay, go to next step. If IGN fuse is defective, repair short in wiring harness and components connected to IGN fuse. See WIRING DIAGRAMS article. Check ignition switch. See IGNITION SWITCH under ENGINE SENSORS & SWITCHES. If ignition switch is okay, go to next step. If ignition switch is defective, replace ignition switch. See IGNITION SWITCH under ENGINE SENSORS & SWITCHES in REMOVAL, OVERHAUL & INSTALLATION - 4-CYLINDER article. Check for open in wiring harness and electrical connectors between ignition switch and EFI main relay, and between body ground and EFI main relay. See WIRING DIAGRAMS article. If wiring harness and electrical connectors are okay, test is complete. If wiring harness or electrical connector is defective, repair as necessary.

ECHO

1. Remove cover from Engine Control Module (ECM) for access to ECM electrical connectors. ECM is located behind glove box. For illustration of ECM location, see THEORY & OPERATION article. Note ECM electrical connector terminals. See Fig. 23 . 2. Turn ignition on. Using voltmeter, check voltage between terminals No. 12 (Black/Red wire) at ECM electrical connector E4 and No. 14 (Brown wire) at ECM electrical connector E7. This is the +B and E1 terminals at ECM. Voltage should be 9-14 volts. If voltage is within specification, diagnose by symptom. See TROUBLE SHOOTING - NO CODES article. If voltage is not within specification, check for open in wiring harness and electrical connectors between terminal No. 14 (Brown wire) at ECM electrical connector E7 and body ground. See WIRING DIAGRAMS article. If wiring harness and electrical connectors are okay, go to next step. If wiring harness or electrical connector is defective, repair as necessary. 3. Check operation of EFI main relay. See EFI MAIN RELAY under MODULES, MOTORS, RELAYS & SOLENOIDS. If EFI main relay operates properly, go to next step. If EFI main relay is defective, replace EFI main relay. 4. Check for defective EFI fuse. EFI fuse is located in fuse/relay box at driver's side front corner of engine compartment, just in front of strut tower, near battery. If EFI fuse is okay, go to next step. If EFI fuse is defective, repair short in wiring harness and components connected to EFI fuse. See WIRING DIAGRAMS article. 5. Check for open in wiring harness and electrical connectors between EFI main relay and battery, and

2002 ENGINE PERFORMANCE System & Component Testing - 4-Cylinder

between EFI main relay and ECM. See WIRING DIAGRAMS article. If wiring harness and electrical connectors are okay, go to next step. If wiring harness or electrical connector is defective, repair as necessary. 6. Check ignition switch. See IGNITION SWITCH under ENGINE SENSORS & SWITCHES. If ignition switch is okay, go to next step. If ignition switch is defective, replace ignition switch. See IGNITION SWITCH under ENGINE SENSORS & SWITCHES in REMOVAL, OVERHAUL & INSTALLATION - 4-CYLINDER article. 7. Check for open in wiring harness and electrical connectors between ignition switch and EFI main relay, and between body ground and EFI main relay. See WIRING DIAGRAMS article. If wiring harness and electrical connectors are okay, test is complete. If wiring harness or electrical connector is defective, repair as necessary.
Highlander

1. Remove glove box for access to Engine Control Module (ECM). For illustration of ECM location, see THEORY & OPERATION article. Note ECM electrical connector terminals. See Fig. 24 . 2. Turn ignition on. Using voltmeter, check voltage between terminals No. 16 (White wire) at ECM electrical connector E5 and No. 17 (Brown wire) at ECM electrical connector E8. This is the +B and E1 terminals at ECM. Voltage should be 9-14 volts. If voltage is not within specification, go to next step. If voltage is within specification, diagnose by symptom. See TROUBLE SHOOTING - NO CODES article. 3. Turn ignition off. Disconnect electrical connector E8 from ECM. Using ohmmeter, check for continuity between body ground and terminal No. 17 (Brown wire) at ECM electrical connector E8. If continuity exists, reinstall electrical connector E8 at ECM and go to next step. If continuity does not exist, repair open in Brown wire between terminal No. 17 at ECM electrical connector E8 and body ground. See WIRING DIAGRAMS article. 4. Ensure ignition is off. Check for open and short in White wire between EFI main relay and terminal No. 16 at ECM electrical connector E5. See WIRING DIAGRAMS article. EFI main relay is located in fuse/relay box at driver's side front corner of engine compartment, just in front of strut tower. If wiring is okay, go to next step. If wiring is defective, repair as necessary. 5. Turn ignition on. Using voltmeter, check voltage between terminals No. 2 (Black/Orange wire) at ECM electrical connector E5 and No. 17 (Brown wire) at ECM electrical connector E8. This is the IGSW and E1 terminals at ECM. Voltage should be 9-14 volts. If voltage is not within specification, go to next step. If voltage is within specification, go to step 10 . 6. Check for defective IGN fuse. IGN fuse is located in fuse box behind driver's side of instrument panel. If IGN fuse is okay, go to next step. If IGN fuse is defective, repair short in wiring harness and components connected to IGN fuse. See WIRING DIAGRAMS article. 7. Check for defective AM2 fuse. AM2 fuse is located in fuse/relay box at driver's side front corner of engine compartment, just in front of strut tower. If AM2 fuse is okay, go to next step. If AM2 fuse is defective, repair short in wiring harness and components connected to AM2 fuse. See WIRING DIAGRAMS article. 8. Check ignition switch. See IGNITION SWITCH under ENGINE SENSORS & SWITCHES. If ignition switch is okay, go to next step. If ignition switch is defective, replace ignition switch. See IGNITION SWITCH under ENGINE SENSORS & SWITCHES in REMOVAL, OVERHAUL & INSTALLATION - 4-CYLINDER article. 9. Check for open in wiring harness and electrical connectors between battery and ignition switch, and between ignition switch and terminal No. 2 (Black/Orange wire) at ECM electrical connector E5. See WIRING DIAGRAMS article. Repair wiring harness or electrical connectors as necessary.

2002 ENGINE PERFORMANCE System & Component Testing - 4-Cylinder

10. Ensure ignition is on. Using voltmeter, check voltage between terminals No. 8 (Pink/Blue wire) at ECM electrical connector E5 and No. 17 (Brown wire) at ECM electrical connector E8. This is the MREL and E1 terminals at ECM. Voltage should be 9-14 volts. If voltage is within specification, go to next step. If voltage is not within specification, check ECM ground circuit. See WIRING DIAGRAMS article. If ECM ground circuit is defective, repair ground circuit as necessary. If ECM ground circuit is okay, replace ECM. On models equipped with engine immobilizer system, if ECM is replaced, ECM must be programmed with proper ignition key code for engine immobilizer system. Models equipped with engine immobilizer system may be identified by looking at the ignition key. On models equipped with engine immobilizer system, the top of the ignition key is thicker than a standard ignition key, as a transponder chip is incorporated into the top of the ignition key. For programming procedures, see COMPUTER RELEARN PROCEDURES article in GENERAL INFORMATION, or appropriate ENGINE IMMOBILIZER SYSTEMS article in ACCESSORIES & EQUIPMENT. 11. Check for defective EFI fuse. EFI fuse is located in fuse/relay box at driver's side front corner of engine compartment, just in front of strut tower. If EFI fuse is okay, go to next step. If EFI fuse is defective, repair short in wiring harness and components connected to EFI fuse. See WIRING DIAGRAMS article. 12. Check operation of EFI main relay. See EFI MAIN RELAY under MODULES, MOTORS, RELAYS & SOLENOIDS. If EFI main relay operates properly, go to next step. If EFI main relay is defective, replace EFI main relay. 13. Check for open and short in wiring harness and electrical connectors between terminal No. 8 (Pink/Blue wire) at ECM electrical connector E5 and EFI main relay, and for open in White/Black wire between EFI main relay and body ground. See WIRING DIAGRAMS article. If wiring harness and electrical connectors are okay, go to next step. If wiring harness or electrical connector is defective, repair as necessary. 14. Check wiring harness and electrical connectors between battery and EFI fuse. See WIRING DIAGRAMS article. Repair wiring harness or and electrical connectors as necessary.
MR2

1. Remove necessary components for access to Engine Control Module (ECM). ECM is located on inside of firewall, directly behind driver's seat and luggage compartment. See ENGINE CONTROL MODULE under COMPUTERIZED ENGINE CONTROLS in REMOVAL, OVERHAUL & INSTALLATION - 4-CYLINDER article. 2. Remove bolts and disconnect ECM with electrical connectors from inside of firewall. Note ECM electrical connector terminals. See Fig. 25 . 3. Turn ignition on. Using voltmeter, check voltage between terminals No. 16 (Black wire) at ECM electrical connector E2 and No. 17 (Brown wire) at ECM electrical connector E4. This is the +B and E1 terminals at ECM. Voltage should be 9-14 volts. If voltage is within specification, diagnose by symptom. See TROUBLE SHOOTING - NO CODES article. If voltage is not within specification, check for open in wiring harness and electrical connectors between terminal No. 17 (Brown wire) at ECM electrical connector E4 and body ground. See WIRING DIAGRAMS article. If wiring harness and electrical connectors are okay, go to next step. If wiring harness or electrical connector is defective, repair as necessary. 4. Turn ignition off. Check for open and short in Black wire between EFI main relay and terminal No. 16 at ECM electrical connector E2. See WIRING DIAGRAMS article. EFI main relay is located in relay box on firewall at driver's side front corner of engine compartment. If wiring is okay, go to next step. If wiring is defective, repair as necessary. 5. Turn ignition on. Using voltmeter, check voltage between body ground and terminal No. 8 (Black/Red wire) at ECM electrical connector E2. This is the IGSW terminal at ECM. Voltage should be 9-14

2002 ENGINE PERFORMANCE System & Component Testing - 4-Cylinder

6.

7.

8.

9.

10.

11.

12.

13.

14.

15.

volts. If voltage is not within specification, go to next step. If voltage is within specification, go to step 11 . Check for defective IG2 fuse. IG2 fuse is located in fuse/relay box at driver's side rear corner of engine compartment, just in front of strut tower. If IG2 fuse is okay, go to next step. If IG2 fuse is defective, repair short in wiring harness and components connected to IGN fuse. See WIRING DIAGRAMS article. Check operation of IG2 relay. See IG2 RELAY under MODULES, MOTORS, RELAYS & SOLENOIDS. If IG2 relay operates properly, go to next step. If IG2 relay is defective, replace IG2 relay. Check for defective AM2 fuse. AM2 fuse is located in fuse/relay box at driver's side rear corner of engine compartment, just in front of strut tower. If AM2 fuse is okay, go to next step. If AM2 fuse is defective, repair short in wiring harness and components connected to AM2 fuse. See WIRING DIAGRAMS article. Check ignition switch. See IGNITION SWITCH under ENGINE SENSORS & SWITCHES. If ignition switch is okay, go to next step. If ignition switch is defective, replace ignition switch. See IGNITION SWITCH under ENGINE SENSORS & SWITCHES in REMOVAL, OVERHAUL & INSTALLATION - 4-CYLINDER article. Check for open in wiring harness and electrical connectors between battery and ignition switch, battery and IG2 relay, ignition switch and IG2 relay, and between IG2 relay and terminal No. 8 (Black/Red wire) at ECM electrical connector E2. See WIRING DIAGRAMS article. Repair wiring harness or electrical connectors as necessary. Ensure ignition is on. Using voltmeter, check voltage between body ground and terminal No. 21 (Gray wire) at ECM electrical connector E3. This is the MREL terminal at ECM. Voltage should be 9-14 volts. If voltage is within specification, go to next step. If voltage is not within specification, check ECM ground circuit. See WIRING DIAGRAMS article. If ECM ground circuit is defective, repair ground circuit as necessary. If ECM ground circuit is okay, replace ECM. On models equipped with engine immobilizer system, if ECM is replaced, ECM must be programmed with proper ignition key code for engine immobilizer system. Models equipped with engine immobilizer system may be identified by looking at the ignition key. On models equipped with engine immobilizer system, the top of the ignition key is thicker than a standard ignition key, as a transponder chip is incorporated into the top of the ignition key. For programming procedures, see COMPUTER RELEARN PROCEDURES article in GENERAL INFORMATION, or appropriate ENGINE IMMOBILIZER SYSTEMS article in ACCESSORIES & EQUIPMENT. Check for defective EFI No. 1 fuse. EFI No. 1 fuse is located in fuse/relay box at driver's side rear corner of engine compartment, just in front of strut tower. EFI No. 1 fuse may also be referred to as EFI1 fuse. If EFI No. 1 fuse is okay, go to next step. If EFI No. 1 fuse is defective, repair short in wiring harness and components connected to EFI No. 1 fuse. See WIRING DIAGRAMS article. Check operation of EFI main relay. See EFI MAIN RELAY under MODULES, MOTORS, RELAYS & SOLENOIDS. If EFI main relay operates properly, go to next step. If EFI main relay is defective, replace EFI main relay. Check for open and short in wiring harness and electrical connectors between terminal No. 21 (Gray wire) at ECM electrical connector E3 and EFI main relay, and for open in White/Black wire between EFI main relay and body ground. See WIRING DIAGRAMS article. If wiring harness and electrical connectors are okay, go to next step. If wiring harness or electrical connector is defective, repair as necessary. Check wiring harness and electrical connectors between battery and EFI No. 1 fuse, and between EFI No. 1 fuse and EFI main relay. See WIRING DIAGRAMS article. Repair wiring harness or and electrical connectors as necessary.

2002 ENGINE PERFORMANCE System & Component Testing - 4-Cylinder

Prius

WARNING: Read service precautions before proceeding with service procedure. See SERVICE PRECAUTIONS . 1. Remove glove box for access to Engine Control Module (ECM). For illustration of ECM location, see THEORY & OPERATION article. Note ECM electrical connector terminals. See Fig. 26 . 2. Turn ignition on. Using voltmeter, check voltage between terminals No. 4 (Black wire) at ECM electrical connector E8 and No. 17 (Brown wire) at ECM electrical connector E8. This is the +B and E1 terminals at ECM. Voltage should be 9-14 volts. If voltage is within specification, diagnose by symptom. See TROUBLE SHOOTING - NO CODES article. If voltage is not within specification, check for open in wiring harness and electrical connectors between terminal No. 17 (Brown wire) at ECM electrical connector E8 and body ground. See WIRING DIAGRAMS article. If wiring harness and electrical connectors are okay, go to next step. If wiring harness or electrical connector is defective, repair as necessary. 3. Turn ignition off. Check for open and short in Black wire between EFI main relay and terminal No. 4 at ECM electrical connector E8. See WIRING DIAGRAMS article. EFI main relay is located in fuse/relay box at driver's side front corner of engine compartment, just in front of strut tower. If wiring is okay, go to next step. If wiring is defective, repair as necessary. 4. Turn ignition on. Using voltmeter, check voltage between body ground and terminal No. 9 (Black/White wire) at ECM electrical connector E10. This is the IGSW terminal at ECM. Voltage should be 9-14 volts. If voltage is not within specification, go to next step. If voltage is within specification, go to step 8 . 5. Check for defective AM2 fuse. AM2 fuse is located in fuse/relay box at driver's side front corner of engine compartment. If AM2 fuse is okay, go to next step. If AM2 fuse is defective, repair short in wiring harness and components connected to AM2 fuse. See WIRING DIAGRAMS article. 6. Check ignition switch. See IGNITION SWITCH under ENGINE SENSORS & SWITCHES. If ignition switch is okay, go to next step. If ignition switch is defective, replace ignition switch. See IGNITION SWITCH under ENGINE SENSORS & SWITCHES in REMOVAL, OVERHAUL & INSTALLATION - 4-CYLINDER article. 7. Check for open in wiring harness and electrical connectors between battery and ignition switch and between ignition switch and terminal No. 9 (Black/White wire) at ECM electrical connector E10. See WIRING DIAGRAMS article. Repair wiring harness or electrical connectors as necessary. 8. Ensure ignition is on. Using voltmeter, check voltage between body ground and terminal No. 25 (Green/Red wire) at ECM electrical connector E9. This is the MREL terminal at ECM. Voltage should be 9-14 volts. If voltage is within specification, go to next step. If voltage is not within specification, check ECM ground circuit. See WIRING DIAGRAMS article. If ECM ground circuit is defective, repair ground circuit as necessary. If ECM ground circuit is okay, replace ECM. 9. Check for defective EFI fuse. EFI fuse is located in fuse/relay box at driver's side front corner of engine compartment. If EFI fuse is okay, go to next step. If EFI fuse is defective, repair short in wiring harness and components connected to EFI fuse. See WIRING DIAGRAMS article. 10. Check operation of EFI main relay. See EFI MAIN RELAY under MODULES, MOTORS, RELAYS & SOLENOIDS. If EFI main relay operates properly, go to next step. If EFI main relay is defective, replace EFI main relay. 11. Check for open and short in wiring harness and electrical connectors between terminal No. 25 (Green/Red wire) at ECM electrical connector E9 and EFI main relay, and for open in White/Black wire between EFI main relay and body ground. See WIRING DIAGRAMS article. If wiring harness and electrical connectors are okay, go to next step. If wiring harness or electrical connector is

2002 ENGINE PERFORMANCE System & Component Testing - 4-Cylinder

defective, repair as necessary. 12. Check wiring harness and electrical connectors between battery and EFI fuse, and between EFI fuse and EFI main relay. See WIRING DIAGRAMS article. Repair wiring harness or and electrical connectors as necessary.
RAV4

1. Remove glove box for access to Engine Control Module (ECM). ECM is located near passenger's side kick panel, just below instrument panel. For illustration of ECM location, see THEORY & OPERATION article. Note ECM electrical connector terminals. See Fig. 27 . 2. Turn ignition on. Using voltmeter, check voltage between terminals No. 16 (Black/Red or Light Green wire) at ECM electrical connector E8 and No. 17 (Brown wire) at ECM electrical connector E5. There are 2 different wiring harnesses used. Wire color at terminal No. 16 may vary according to wiring harness used. This is the +B and E1 terminals at ECM. Voltage should be 9-14 volts. If voltage is within specification, diagnose by symptom. See TROUBLE SHOOTING - NO CODES article. If voltage is not within specification, check for open in wiring harness and electrical connectors between terminal No. 17 (Brown wire) at ECM electrical connector E5 and body ground. See WIRING DIAGRAMS article. If wiring harness and electrical connectors are okay, go to next step. If wiring harness or electrical connector is defective, repair as necessary. 3. Turn ignition off. Check for open and short in Black/Red or Light Green wire between EFI main relay and terminal No. 16 at ECM electrical connector E8. See WIRING DIAGRAMS article. EFI main relay is located in fuse/relay box at driver's side front corner of engine compartment, just in front of strut tower. If wiring is okay, go to next step. If wiring is defective, repair as necessary. 4. Turn ignition on. Using voltmeter, check voltage between body ground and terminal No. 2 (Black/Orange or White wire) at ECM electrical connector E8. This is the IGSW terminal at ECM. Voltage should be 9-14 volts. If voltage is not within specification, go to next step. If voltage is within specification, go to step 9 . 5. Check for defective IG2 fuse. IG2 fuse is located in fuse box behind driver's side of instrument panel. If IG2 fuse is okay, go to next step. If IG2 fuse is defective, repair short in wiring harness and components connected to IG2 fuse. See WIRING DIAGRAMS article. 6. Check for defective AM2 fuse. AM2 fuse is located in fuse/relay box at driver's side front corner of engine compartment. If AM2 fuse is okay, go to next step. If AM2 fuse is defective, repair short in wiring harness and components connected to AM2 fuse. See WIRING DIAGRAMS article. 7. Check ignition switch. See IGNITION SWITCH under ENGINE SENSORS & SWITCHES. If ignition switch is okay, go to next step. If ignition switch is defective, replace ignition switch. See IGNITION SWITCH under ENGINE SENSORS & SWITCHES in REMOVAL, OVERHAUL & INSTALLATION - 4-CYLINDER article. 8. Check for open in wiring harness and electrical connectors between battery and ignition switch, and between ignition switch and terminal No. 2 (Black/Orange or White wire) at ECM electrical connector E8. See WIRING DIAGRAMS article. Repair wiring harness or electrical connectors as necessary. 9. Ensure ignition is on. Using voltmeter, check voltage between body ground and terminal No. 8 (Green/White or White wire) at ECM electrical connector E8. This is the MREL terminal at ECM. Voltage should be 9-14 volts. If voltage is within specification, go to next step. If voltage is not within specification, check ECM ground circuit. See WIRING DIAGRAMS article. If ECM ground circuit is defective, repair ground circuit as necessary. If ECM ground circuit is okay, replace ECM. On models equipped with engine immobilizer system, if ECM is replaced, ECM must be programmed with proper ignition key code for engine immobilizer system. Models equipped with engine immobilizer system may be identified by looking at the ignition key. On models equipped with engine immobilizer system, the top of the ignition key is thicker than a standard ignition key, as a

2002 ENGINE PERFORMANCE System & Component Testing - 4-Cylinder

10.

11.

12.

13.

transponder chip is incorporated into the top of the ignition key. For programming procedures, see COMPUTER RELEARN PROCEDURES article in GENERAL INFORMATION, or appropriate ENGINE IMMOBILIZER SYSTEMS article in ACCESSORIES & EQUIPMENT. Check for defective EFI No. 1 fuse. EFI No. 1 fuse is located in fuse/relay box at driver's side front corner of engine compartment. EFI No. 1 fuse may also be referred to as EFI1 fuse. If EFI No. 1 fuse is okay, go to next step. If EFI No. 1 fuse is defective, repair short in wiring harness and components connected to EFI No. 1 fuse. See WIRING DIAGRAMS article. Check operation of EFI main relay. See EFI MAIN RELAY under MODULES, MOTORS, RELAYS & SOLENOIDS. If EFI main relay operates properly, go to next step. If EFI main relay is defective, replace EFI main relay. Check for open in wiring harness and electrical connectors between EFI main relay, EFI No. 1 fuse and battery. See WIRING DIAGRAMS article. If wiring harness and electrical connectors are okay, go to next step. If wiring harness or electrical connector is defective, repair as necessary. Check for open and short in wiring harness and electrical connectors between terminal No. 8 (Green/White or White wire) at ECM electrical connector E8 and EFI main relay, and for open in White/Black wire between EFI main relay and body ground. See WIRING DIAGRAMS article. If wiring harness and electrical connectors are okay, test is complete. If wiring harness or electrical connector is defective, repair as necessary.

Tacoma

1. Remove glove box for access to ECM. For illustration of ECM location, see THEORY & OPERATION article. Note ECM electrical connector terminals. See Fig. 28 . 2. Turn ignition on. Using voltmeter, check voltage between terminals No. 16 (White/Red wire) at ECM electrical connector E5 and No. 17 (Brown wire) at ECM electrical connector E7. This is the +B and E1 terminals at ECM. Voltage should be 9-14 volts. If voltage is within specification, diagnose by symptom. See TROUBLE SHOOTING - NO CODES article. If voltage is not within specification, check for open in wiring harness and electrical connectors between terminal No. 17 (Brown wire) at ECM electrical connector E7 and body ground. See WIRING DIAGRAMS article. If wiring harness and electrical connectors are okay, go to next step. If wiring harness or electrical connector is defective, repair as necessary. 3. Check operation of EFI main relay. See EFI MAIN RELAY under MODULES, MOTORS, RELAYS & SOLENOIDS. If EFI main relay operates properly, go to next step. If EFI main relay is defective, replace EFI main relay. 4. Check for defective EFI fuse. EFI fuse is located in fuse/relay box at driver's side front corner of engine compartment, next to battery. If EFI fuse is okay, go to next step. If EFI fuse is defective, repair short in wiring harness and components connected to EFI fuse. See WIRING DIAGRAMS article. 5. Check for open in wiring harness and electrical connectors between EFI main relay and battery, and between EFI main relay and terminals No. 16 (White/Red wire) at ECM electrical connector E5. See WIRING DIAGRAMS article. If wiring harness and electrical connectors are okay, go to next step. If wiring harness or electrical connector is defective, repair as necessary. 6. Check for defective IGN fuse. IGN fuse is located in fuse/relay box behind driver's side of instrument panel. If IGN fuse is okay, go to next step. If IGN fuse is defective, repair short in wiring harness and components connected to IGN fuse. See WIRING DIAGRAMS article. 7. Check ignition switch. See IGNITION SWITCH under ENGINE SENSORS & SWITCHES. If ignition switch is okay, go to next step. If ignition switch is defective, replace ignition switch. See IGNITION SWITCH under ENGINE SENSORS & SWITCHES in REMOVAL, OVERHAUL & INSTALLATION - 4-CYLINDER article.

2002 ENGINE PERFORMANCE System & Component Testing - 4-Cylinder

8. Check for open in wiring harness and electrical connectors between ignition switch and EFI main relay, and for open in White/Black wire between EFI main relay and body ground. See WIRING DIAGRAMS article. If wiring harness and electrical connectors are okay, test is complete. If wiring harness or electrical connector is defective, repair as necessary. FUEL PUMP CONTROL CIRCUIT CAUTION: If Engine Control Module (ECM) replacement is instructed in the following testing, always ensure ECM wiring harness electrical connector and ground circuit are okay. If either are defective, repair and repeat testing to confirm ECM malfunction.
Camry, Camry Solara, Celica, Corolla, ECHO, Highlander, MR2, Prius, RAV4 & Tacoma

WARNING: On Prius, read service precautions before proceeding with service procedure. See SERVICE PRECAUTIONS . 1. If Toyota hand-held tester is available, go to next step. If Toyota hand-held tester is not available, go to step 3 . 2. Check operation of fuel pump by using Toyota hand-held tester. See FUEL PUMP OPERATION under FUEL SYSTEMS in BASIC DIAGNOSTIC PROCEDURES - 4-CYLINDER article. If fuel pump does not operate when using hand-held tester, go to step 5 . If fuel pump operates when using hand-held tester, diagnose by symptom. See TROUBLE SHOOTING - NO CODES article. 3. Remove necessary components for access to Engine Control Module (ECM). See ENGINE CONTROL MODULE LOCATION table. 4. Note ECM terminals. See Fig. 18 -Fig. 28 . Turn ignition on. Momentarily connect jumper wire between body ground and FC terminal at ECM and listen for fuel pump operating sound. See ECM IDENTIFICATION FOR FUEL PUMP FC TERMINAL table. On Camry, Celica, Corolla, ECHO, Highlander, MR2, Prius and RAV4, feel for fuel pressure in fuel inlet line at end of fuel rail when fuel inlet line is pinched closed. On Camry Solara, feel for fuel pressure in fuel inlet line at fuel filter when fuel inlet line is pinched closed. On Tacoma, feel for fuel pressure in fuel return line from fuel pressure regulator when fuel return line is pinched closed. On all models, if fuel pump does not operate when jumper wire was connected, go to next step. If fuel pump operates when jumper wire was connected, diagnose by symptom. See TROUBLE SHOOTING - NO CODES article. 5. Check ECM power source circuit. See ENGINE CONTROL MODULE POWER SOURCE CIRCUIT . If ECM power source circuit is okay, go to next step. If ECM power source circuit is defective, repair as necessary. 6. Check circuit opening relay. See CIRCUIT OPENING RELAY under MODULES, MOTORS, RELAYS & SOLENOIDS. If circuit opening relay is okay, go to next step. If circuit opening relay is defective, replace circuit opening relay. 7. Remove necessary components for access to ECM if not previously done. See ENGINE CONTROL MODULE LOCATION table. ENGINE CONTROL MODULE LOCATION Model Camry & Camry Solara
(1) Location

Behind Glove Box

2002 ENGINE PERFORMANCE System & Component Testing - 4-Cylinder

Celica

In Engine Compartment, Below Cover, Just In Front Of Battery, Next To Driver's Side Strut Tower Corolla Behind Stereo On Instrument Panel, Just In Front Of Center Console ECHO & Highlander Behind Glove Box MR2 On Inside Of Firewall, Directly Behind Driver's Seat & Luggage Compartment Prius Behind Glove Box RAV4 Near Passenger's Side Kick Panel, Just Below Instrument Panel Tacoma Behind Glove Box (1) For illustration of ECM location, see THEORY & OPERATION article. 8. Note ECM terminals. See Fig. 18 -Fig. 28 . Turn ignition on. Using voltmeter, check voltage between body ground and FC terminal at ECM. See ECM IDENTIFICATION FOR FUEL PUMP FC TERMINAL table. ECM IDENTIFICATION FOR FUEL PUMP FC TERMINAL ECM Terminal No. (Wire Color) Application ECM Connector Camry E6 10 (Green/Red) Camry E7 10 (Green/Red) Solara Celica E2 3 (Green/Red) Corolla 3-Speed E6 14 (Green/Red) A/T & M/T 4-Speed E10 3 (Green/Red) A/T ECHO E4 14 (Green) Highlander E5 3 (Green/Red) MR2 E2 3 (Green/Red) Prius E8 9 (Green/Red) (1) 3 (Green/Red Or RAV4 E8 White) Tacoma E6 6 (White/Blue) (1) There are 2 different wiring harnesses used. Wire color at designated terminal may vary according to wiring harness used. 9. Voltage should be 9-14 volts. If voltage is within specification, go to next step. On Camry, Camry Solara, Highlander, MR2, RAV4 and Tacoma, if voltage is not within specification, check for open in

2002 ENGINE PERFORMANCE System & Component Testing - 4-Cylinder

wiring harness and connectors between ECM and circuit opening relay, and between ignition switch and circuit opening relay. See WIRING DIAGRAMS article. On Celica, Corolla, ECHO and Prius, if voltage is not within specification, check for open in wiring harness and connectors between ECM and circuit opening relay, and between EFI main relay and circuit opening relay. See WIRING DIAGRAMS article. For EFI main relay location, see EFI MAIN RELAY under MODULES, MOTORS, RELAYS & SOLENOIDS. On all models, if wiring harness or electrical connector is defective, repair as necessary. 10. Check fuel pump resistance and operation. See FUEL DELIVERY under FUEL SYSTEMS. If fuel pump resistance is within specification and fuel pump operates, go to next step. If fuel pump resistance is not within specification or fuel pump does not operate, replace fuel pump. See FUEL PUMP under FUEL SYSTEMS in REMOVAL, OVERHAUL & INSTALLATION - 4-CYLINDER article. 11. Check for open in wiring harness and electrical connectors between circuit opening relay and fuel pump, and between fuel pump and body ground. See WIRING DIAGRAMS article. On Camry, Camry Solara, Highlander, MR2, RAV4 and Tacoma, also check for open in wiring harness and electrical connectors between circuit opening relay and EFI main relay. See WIRING DIAGRAMS article. For EFI main relay location, see EFI MAIN RELAY under MODULES, MOTORS, RELAYS & SOLENOIDS. On all models, if wiring harness and electrical connectors are okay, go to next step. If wiring harness or electrical connector is defective, repair as necessary. 12. Check ECM ground circuit. See WIRING DIAGRAMS article. If ECM ground circuit is defective, repair ground circuit as necessary. If ECM ground circuit is okay, replace ECM. On Camry, Camry Solara, Highlander, MR2 and RAV4, if ECM is replaced and vehicle is equipped with engine immobilizer system, ECM must be programmed with proper ignition key code for engine immobilizer system. Models equipped with engine immobilizer system may be identified by looking at the ignition key. On models equipped with engine immobilizer system, the top of the ignition key is thicker than a standard ignition key, as a transponder chip is incorporated into the top of the ignition key. For programming procedures, see COMPUTER RELEARN PROCEDURES article in GENERAL INFORMATION, or appropriate ENGINE IMMOBILIZER SYSTEMS article in ACCESSORIES & EQUIPMENT. STARTER SIGNAL CIRCUIT NOTE: Starter signal circuit is mainly used to increase fuel injection volume during engine starting. Starter signal circuit test is based on the premise that engine cranks normally. If engine will not crank, diagnose by symptom. See TROUBLE SHOOTING - NO CODES article. CAUTION: If Engine Control Module (ECM) replacement is instructed in the following testing, always ensure ECM wiring harness electrical connector and ground circuit are okay. If either are defective, repair and repeat testing to confirm ECM malfunction. NOTE: When performing starter signal circuit test, it may be necessary to consult the starter wiring diagram for the entire wiring circuit. For starter wiring diagram, see WIRING DIAGRAMS in appropriate STARTERS article in STARTING & CHARGING SYSTEMS.

Camry & Camry Solara

2002 ENGINE PERFORMANCE System & Component Testing - 4-Cylinder

1. If Toyota hand-held tester is available, go to next step. If Toyota hand-held tester is not available, go to step 5 . 2. Connect hand-held tester to data link connector No. 3 at driver's side of instrument panel. See Fig. 8 and Fig. 9 . Turn ignition on and then turn hand-held tester on. Read STA signal display on hand-held tester with ignition on, and with ignition switch in START position and engine cranking. STA signal display should read OFF with ignition on, and ON with ignition switch in START position. If STA signal display is not as specified, go to next step. If STA signal display is as specified, diagnose by symptom. See TROUBLE SHOOTING - NO CODES article. 3. Check for open in Black/White wire (Camry) or Gray wire (Camry Solara) and electrical connectors between STA terminal at Engine Control Module (ECM) and park/neutral position switch (A/T) or clutch start switch (M/T). See WIRING DIAGRAMS article. Park/neutral position switch is located on side of transaxle and clutch start switch is located near top of clutch pedal. See ECM TERMINAL IDENTIFICATION FOR STARTER SIGNAL (CAMRY & CAMRY SOLARA) table. ECM is located behind glove box. For illustration of ECM location, see THEORY & OPERATION article. For ECM electrical connector terminal identification, see Fig. 18 and Fig. 19 . 4. If wiring harness or electrical connector is defective, repair as necessary. If wiring harness and electrical connectors are okay, check ECM ground circuit. See WIRING DIAGRAMS article. If ECM ground circuit is defective, repair ground circuit as necessary. If ECM ground circuit is okay, replace ECM. On models equipped with engine immobilizer system, if ECM is replaced, ECM must be programmed with proper ignition key code for engine immobilizer system. Models equipped with engine immobilizer system may be identified by looking at the ignition key. On models equipped with engine immobilizer system, the top of the ignition key is thicker than a standard ignition key, as a transponder chip is incorporated into the top of the ignition key. For programming procedures, see COMPUTER RELEARN PROCEDURES article in GENERAL INFORMATION, or appropriate ENGINE IMMOBILIZER SYSTEMS article in ACCESSORIES & EQUIPMENT. 5. Remove glove box for access to Engine Control Module (ECM). For illustration of ECM location, see THEORY & OPERATION article. Note ECM electrical connector terminals. See Fig. 18 and Fig. 19 . Using voltmeter, check voltage between body ground and STA terminal (starter signal wire) at ECM with ignition switch in START position and engine cranking. See ECM TERMINAL IDENTIFICATION FOR STARTER SIGNAL (CAMRY & CAMRY SOLARA) table. ECM TERMINAL IDENTIFICATION FOR STARTER SIGNAL (CAMRY & CAMRY SOLARA) ECM Terminal No. Application ECM Connector (Wire Color) Camry E9 9 (Black/White) Camry Solara E10 9 (Gray) 6. Voltage should be 6 volts or more. If voltage is not within specification, go to next step. If voltage is within specification, diagnose by symptom. See TROUBLE SHOOTING - NO CODES article. 7. Check for open in Black/White wire (Camry) or Gray wire (Camry Solara) and electrical connectors between STA terminal at ECM and park/neutral position switch (A/T) or clutch start switch (M/T). See WIRING DIAGRAMS article. Park/neutral position switch is located on side of transaxle and clutch start switch is located near top of clutch pedal. If wiring harness and electrical connectors are okay, go to next step. If wiring harness or electrical connector is defective, repair as necessary. If ECM ground circuit is okay, replace ECM. On models equipped with engine immobilizer system, if ECM is replaced, ECM must be programmed with proper ignition key code for engine immobilizer system. Models equipped with engine immobilizer system may be identified by looking at the ignition key. On models equipped with engine immobilizer system, the top of the ignition key is thicker than a

2002 ENGINE PERFORMANCE System & Component Testing - 4-Cylinder

standard ignition key, as a transponder chip is incorporated into the top of the ignition key. For programming procedures, see COMPUTER RELEARN PROCEDURES article in GENERAL INFORMATION, or appropriate ENGINE IMMOBILIZER SYSTEMS article in ACCESSORIES & EQUIPMENT.
Celica & ECHO

Testing information is not available from manufacturer.

Corolla

1. If Toyota hand-held tester is available, go to next step. If Toyota hand-held tester is not available, go to step 5 . 2. Connect hand-held tester to data link connector No. 3 at driver's side of instrument panel. See Fig. 11 . Turn ignition on and then turn hand-held tester on. Read STA signal display on hand-held tester with ignition on, and with ignition switch in START position and engine cranking. STA signal display should read OFF with ignition on, and ON with ignition switch in START position. If STA signal display is not as specified, go to next step. If STA signal display is as specified, diagnose by symptom. See TROUBLE SHOOTING - NO CODES article. 3. Check for open in Black/White wire (starter signal wire) and electrical connectors between starter relay and terminal No. 11 at Engine Control Module (ECM) electrical connector E6 on 3-speed A/T and M/T models, or terminal No. 11 at ECM electrical connector E9 on 4-speed A/T models. See WIRING DIAGRAMS article. ECM is located behind stereo on instrument panel, just in front of center console. For illustration of ECM location, see THEORY & OPERATION article. Starter relay is located in fuse/relay box at driver's side front corner of engine compartment, just in front of strut tower and may be marked as ST relay. For ECM electrical connector terminal identification, see Fig. 21 and Fig. 22 . 4. If wiring harness or electrical connector is defective, repair as necessary. If wiring harness and electrical connectors are okay, check ECM ground circuit. See WIRING DIAGRAMS article. If ECM ground circuit is defective, repair ground circuit as necessary. If ECM ground circuit is okay, replace ECM. 5. Remove necessary components for access to Engine Control Module (ECM). See ENGINE CONTROL MODULE under COMPUTERIZED ENGINE CONTROLS in REMOVAL, OVERHAUL & INSTALLATION - 4-CYLINDER article. Remove bolts from ECM so electrical connectors can be accessed on ECM. 6. Note ECM electrical connector terminals. See Fig. 21 and Fig. 22 . On 3-speed A/T and M/T models, using voltmeter, check voltage between body ground and terminal No. 11 (Black/White wire) at ECM electrical connector E6 with ignition switch in START position and engine cranking. On 4-speed A/T models, using voltmeter, check voltage between body ground and terminal No. 11 (Black/White wire) at ECM electrical connector E9 with ignition switch in START position and engine cranking. On all models, this is the STA terminal at ECM. 7. On all models, voltage should be 6 volts or more. If voltage is not within specification, go to next step. If voltage is within specification, diagnose by symptom. See TROUBLE SHOOTING - NO CODES article. 8. Check for open and short in Black/White wire and electrical connectors between starter relay and terminal No. 11 at ECM electrical connector E6 on 3-speed A/T and M/T models, or terminal No. 11 at ECM electrical connector E9 on 4-speed A/T models. See WIRING DIAGRAMS article. This is the starter signal wire. Starter relay is located in fuse/relay box at driver's side front corner of engine compartment, just in front of strut tower and may be marked as ST relay.

2002 ENGINE PERFORMANCE System & Component Testing - 4-Cylinder

9. If wiring harness or electrical connector is defective, repair as necessary. If wiring harness and electrical connectors are okay, check ECM ground circuit. See WIRING DIAGRAMS article. If ECM ground circuit is defective, repair ground circuit as necessary. If ECM ground circuit is okay, replace ECM.
Highlander

1. If Toyota hand-held tester is available, go to next step. If Toyota hand-held tester is not available, go to step 5 . 2. Connect hand-held tester to data link connector No. 3 at driver's side of instrument panel. See Fig. 13 . Turn ignition on and then turn hand-held tester on. Read STA signal display on hand-held tester with ignition on, and with ignition switch in START position and engine cranking. STA signal display should read OFF with ignition on, and ON with ignition switch in START position. If STA signal display is not as specified, go to next step. If STA signal display is as specified, diagnose by symptom. See TROUBLE SHOOTING - NO CODES article. 3. Check for open and short in White/Red wire between starter relay and starter fuse, defective starter fuse, and for open and short in Blue wire and electrical connectors between starter fuse and terminal No. 16 at Engine Control Module (ECM) electrical connector E7. This is the starter signal circuit between starter relay and ECM. See WIRING DIAGRAMS article. Starter relay and starter fuse are located in fuse/relay box at driver's side front corner of engine compartment, just in front of strut tower. ECM is located behind glove box. For illustration of ECM location, see THEORY & OPERATION article. For ECM electrical connector terminal identification, see Fig. 24 . 4. If starter fuse, wiring harness or electrical connector is defective, replace fuse or repair wiring harness or electrical connector as necessary. If starter fuse, wiring harness and electrical connectors are okay, check ECM ground circuit. See WIRING DIAGRAMS article. If ECM ground circuit is defective, repair ground circuit as necessary. If ECM ground circuit is okay, replace ECM. On models equipped with engine immobilizer system, if ECM is replaced, ECM must be programmed with proper ignition key code for engine immobilizer system. Models equipped with engine immobilizer system may be identified by looking at the ignition key. On models equipped with engine immobilizer system, the top of the ignition key is thicker than a standard ignition key, as a transponder chip is incorporated into the top of the ignition key. For programming procedures, see COMPUTER RELEARN PROCEDURES article in GENERAL INFORMATION, or appropriate ENGINE IMMOBILIZER SYSTEMS article in ACCESSORIES & EQUIPMENT. 5. Remove glove box for access to Engine Control Module (ECM). For illustration of ECM location, see THEORY & OPERATION article. 6. Note ECM electrical connector terminals. See Fig. 24 . Using voltmeter, check voltage between body ground and terminal No. 16 (Blue wire) at ECM electrical connector E7 with ignition switch in START position and engine cranking. See Fig. 24 . This is the STA terminal at ECM. Voltage should be 6 volts or more. If voltage is not within specification, go to next step. If voltage is within specification, diagnose by symptom. See TROUBLE SHOOTING - NO CODES article. 7. Check for open and short in White/Red wire between starter relay and starter fuse, defective starter fuse, and for open and short in Blue wire and electrical connectors between starter fuse and terminal No. 16 at ECM electrical connector E7. This is the starter signal circuit between starter relay and ECM. See WIRING DIAGRAMS article. Starter relay and starter fuse are located in fuse/relay box at driver's side front corner of engine compartment, just in front of strut tower. 8. If starter fuse, wiring harness or electrical connector is defective, replace fuse or repair wiring harness or electrical connector as necessary. If starter fuse, wiring harness and electrical connectors are okay, check ECM ground circuit. See WIRING DIAGRAMS article. If ECM ground circuit is defective, repair ground circuit as necessary. If ECM ground circuit is okay, replace ECM. On models equipped

2002 ENGINE PERFORMANCE System & Component Testing - 4-Cylinder

with engine immobilizer system, if ECM is replaced, ECM must be programmed with proper ignition key code for engine immobilizer system. Models equipped with engine immobilizer system may be identified by looking at the ignition key. On models equipped with engine immobilizer system, the top of the ignition key is thicker than a standard ignition key, as a transponder chip is incorporated into the top of the ignition key. For programming procedures, see COMPUTER RELEARN PROCEDURES article in GENERAL INFORMATION, or appropriate ENGINE IMMOBILIZER SYSTEMS article in ACCESSORIES & EQUIPMENT.
MR2

1. If Toyota hand-held tester is available, go to next step. If Toyota hand-held tester is not available, go to step 5 . 2. Connect hand-held tester to data link connector No. 3 at driver's side of instrument panel. See Fig. 14 . Turn ignition on and then turn hand-held tester on. Read STA signal display on hand-held tester with ignition on, and with ignition switch in START position and engine cranking. STA signal display should read OFF with ignition on, and ON with ignition switch in START position. If STA signal display is not as specified, go to next step. If STA signal display is as specified, diagnose by symptom. See TROUBLE SHOOTING - NO CODES article. 3. Check for open and short in Black wire between starter relay and starter fuse, defective starter fuse, and for open and short in Black wire and electrical connectors between starter fuse and terminal No. 11 at Engine Control Module (ECM) electrical connector E3. This is the starter signal circuit between starter relay and ECM. See WIRING DIAGRAMS article. Starter relay and starter fuse are located in fuse/relay box at driver's side rear corner of engine compartment, just in front of strut tower and may be marked as ST relay and ST fuse. ECM is located on inside of firewall, directly behind driver's seat and luggage compartment. For illustration of ECM location, see THEORY & OPERATION article. To remove components for access to ECM, see ENGINE CONTROL MODULE under COMPUTERIZED ENGINE CONTROLS in REMOVAL, OVERHAUL & INSTALLATION - 4CYLINDER article. For ECM electrical connector terminal identification, see Fig. 25 . 4. If starter fuse, wiring harness or electrical connector is defective, replace fuse or repair wiring harness or electrical connector as necessary. If starter fuse, wiring harness and electrical connectors are okay, check ECM ground circuit. See WIRING DIAGRAMS article. If ECM ground circuit is defective, repair ground circuit as necessary. If ECM ground circuit is okay, replace ECM. On models equipped with engine immobilizer system, if ECM is replaced, ECM must be programmed with proper ignition key code for engine immobilizer system. Models equipped with engine immobilizer system may be identified by looking at the ignition key. On models equipped with engine immobilizer system, the top of the ignition key is thicker than a standard ignition key, as a transponder chip is incorporated into the top of the ignition key. For programming procedures, see COMPUTER RELEARN PROCEDURES article in GENERAL INFORMATION, or appropriate ENGINE IMMOBILIZER SYSTEMS article in ACCESSORIES & EQUIPMENT. 5. Remove necessary components for access to Engine Control Module (ECM). ECM is located on inside of firewall, directly behind driver's seat and luggage compartment. See ENGINE CONTROL MODULE under COMPUTERIZED ENGINE CONTROLS in REMOVAL, OVERHAUL & INSTALLATION - 4-CYLINDER article. Remove bolts and disconnect ECM with electrical connectors from inside of firewall. 6. Note ECM electrical connector terminals. See Fig. 25 . Using voltmeter, check voltage between body ground and terminal No. 11 (Black wire) at ECM electrical connector E3 with ignition switch in START position and engine cranking. This is the STA terminal at ECM. Voltage should be 6 volts or more. If voltage is not within specification, go to next step. If voltage is within specification, diagnose by symptom. See TROUBLE SHOOTING - NO CODES article. 7. Check for open and short in Black wire between starter relay and starter fuse, defective starter fuse,

2002 ENGINE PERFORMANCE System & Component Testing - 4-Cylinder

and for open and short in Black wire and electrical connectors between starter relay and terminal No. 11 at ECM electrical connector E3. This is the starter signal circuit between starter relay and ECM. See WIRING DIAGRAMS article. Starter relay and starter fuse are located in fuse/relay box at driver's side rear corner of engine compartment, just in front of strut tower and may be marked as ST relay and ST fuse. 8. If starter fuse, wiring harness or electrical connector is defective, replace fuse or repair wiring harness or electrical connector as necessary. If starter fuse, wiring harness and electrical connectors are okay, check ECM ground circuit. See WIRING DIAGRAMS article. If ECM ground circuit is defective, repair ground circuit as necessary. If ECM ground circuit is okay, replace ECM. On models equipped with engine immobilizer system, if ECM is replaced, ECM must be programmed with proper ignition key code for engine immobilizer system. Models equipped with engine immobilizer system may be identified by looking at the ignition key. On models equipped with engine immobilizer system, the top of the ignition key is thicker than a standard ignition key, as a transponder chip is incorporated into the top of the ignition key. For programming procedures, see COMPUTER RELEARN PROCEDURES article in GENERAL INFORMATION, or appropriate ENGINE IMMOBILIZER SYSTEMS article in ACCESSORIES & EQUIPMENT.
Prius

Testing information is not available from manufacturer.

RAV4

1. If Toyota hand-held tester is available, go to next step. If Toyota hand-held tester is not available, go to step 5 . 2. Connect hand-held tester to data link connector No. 3 at driver's side of instrument panel. See Fig. 16 . Turn ignition on and then turn hand-held tester on. Read STA signal display on hand-held tester with ignition on, and with ignition switch in START position and engine cranking. STA signal display should read OFF with ignition on, and ON with ignition switch in START position. If STA signal display is not as specified, go to next step. If STA signal display is as specified, diagnose by symptom. See TROUBLE SHOOTING - NO CODES article. 3. Check for open and short in Black/White wire between starter relay and starter fuse, defective starter fuse, and for open and short in Black/Red or White wire and electrical connectors between starter fuse and terminal No. 7 (Black/Red or White wire) at Engine Control Module (ECM) electrical connector E8. There are 2 different wiring harnesses used. Wire color at between starter fuse and terminal No. 7 at ECM may vary according to wiring harness used. This is the starter signal circuit between starter relay and ECM. See WIRING DIAGRAMS article. Starter relay and starter fuse are located in fuse/relay box at driver's side front corner of engine compartment and may be marked as ST relay and ST fuse. ECM is located near passenger's side kick panel, just below instrument panel. For illustration of ECM location, see THEORY & OPERATION article. For ECM electrical connector terminal identification, see Fig. 27 . 4. If starter fuse, wiring harness or electrical connector is defective, replace fuse or repair wiring harness or electrical connector as necessary. If starter fuse, wiring harness and electrical connectors are okay, check ECM ground circuit. See WIRING DIAGRAMS article. If ECM ground circuit is defective, repair ground circuit as necessary. If ECM ground circuit is okay, replace ECM. On models equipped with engine immobilizer system, if ECM is replaced, ECM must be programmed with proper ignition key code for engine immobilizer system. Models equipped with engine immobilizer system may be identified by looking at the ignition key. On models equipped with engine immobilizer system, the top of the ignition key is thicker than a standard ignition key, as a transponder chip is incorporated into the top of the ignition key. For programming procedures, see COMPUTER RELEARN

2002 ENGINE PERFORMANCE System & Component Testing - 4-Cylinder

5. 6.

7.

8.

PROCEDURES article in GENERAL INFORMATION, or appropriate ENGINE IMMOBILIZER SYSTEMS article in ACCESSORIES & EQUIPMENT. Remove glove box for access to Engine Control Module (ECM). For illustration of ECM location, see THEORY & OPERATION article. Note ECM electrical connector terminals, see Fig. 27 . Using voltmeter, check voltage between body ground and terminal No. 7 (Black/Red or White wire) at ECM electrical connector E8 with ignition switch in START position and engine cranking. There are 2 different wiring harnesses used. Wire color at terminal No. 7 at ECM may vary according to wiring harness used. This is the STA terminal at ECM. Voltage should be 6 volts or more. If voltage is not within specification, go to next step. If voltage is within specification, diagnose by symptom. See TROUBLE SHOOTING - NO CODES article. Check for open and short in Black/White wire between starter relay and starter fuse, defective starter fuse, and for open and short in Black/Red or White wire and electrical connectors between starter fuse and terminal No. 7 at ECM electrical connector E8. This is the starter signal circuit between starter relay and ECM. See WIRING DIAGRAMS article. Starter relay and starter fuse are located in fuse/relay box at driver's side front corner of engine compartment and may be marked as ST relay and ST fuse. If starter fuse, wiring harness or electrical connector is defective, replace fuse or repair wiring harness or electrical connector as necessary. If starter fuse, wiring harness and electrical connectors are okay, check ECM ground circuit. See WIRING DIAGRAMS article. If ECM ground circuit is defective, repair ground circuit as necessary. If ECM ground circuit is okay, replace ECM. On models equipped with engine immobilizer system, if ECM is replaced, ECM must be programmed with proper ignition key code for engine immobilizer system. Models equipped with engine immobilizer system may be identified by looking at the ignition key. On models equipped with engine immobilizer system, the top of the ignition key is thicker than a standard ignition key, as a transponder chip is incorporated into the top of the ignition key. For programming procedures, see COMPUTER RELEARN PROCEDURES article in GENERAL INFORMATION, or appropriate ENGINE IMMOBILIZER SYSTEMS article in ACCESSORIES & EQUIPMENT.

Tacoma

1. If Toyota hand-held tester is available, go to next step. If Toyota hand-held tester is not available, go to step 5 . 2. Connect hand-held tester to data link connector No. 3 at driver's side of instrument panel. See Fig. 17 . Turn ignition on and then turn hand-held tester on. Read STA signal display on hand-held tester with ignition on, and with ignition switch in START position and engine cranking. STA signal display should read OFF with ignition on, and ON with ignition switch in START position. If STA signal display is not as specified, go to next step. If STA signal display is as specified, diagnose by symptom. See TROUBLE SHOOTING - NO CODES article. 3. Check for open in Black/White wire between park/neutral position switch (A/T) or clutch start switch (M/T) and terminal No. 7 at Engine Control Module (ECM) electrical connector E5. This is the starter signal circuit to ECM. See WIRING DIAGRAMS article. ECM is located behind glove box. For illustration of ECM location, see THEORY & OPERATION article. For ECM electrical connector terminal identification, see Fig. 28 . Park/neutral position switch is located on side of transmission and clutch start switch is located near top of clutch pedal. 4. If wiring harness or electrical connector is defective, repair as necessary. If wiring harness and electrical connectors are okay, check ECM ground circuit. See WIRING DIAGRAMS article. If ECM ground circuit is defective, repair ground circuit as necessary. If ECM ground circuit is okay, replace ECM.

2002 ENGINE PERFORMANCE System & Component Testing - 4-Cylinder

5. Remove glove box for access to Engine Control Module (ECM). For illustration of ECM location, see THEORY & OPERATION article. 6. Note ECM electrical connector terminals. See Fig. 28 . Using voltmeter, check voltage body ground and terminal No. 7 (Black/White wire) at ECM electrical connector E5 with ignition switch in START position and engine cranking. This is the STA terminal at ECM. Voltage should be 6 volts or more. If voltage is not within specification, go to next step. If voltage is within specification, diagnose by symptom. See TROUBLE SHOOTING - NO CODES article. 7. Check for open in Black/White wire between park/neutral position switch (A/T) or clutch start switch (M/T) and terminal No. 7 at ECM electrical connector E5. This is the starter signal circuit to ECM. See WIRING DIAGRAMS article. Park/neutral position switch is located on side of transmission and clutch start switch is located near top of clutch pedal. 8. If wiring harness or electrical connector is defective, repair as necessary. If wiring harness and electrical connectors are okay, check ECM ground circuit. See WIRING DIAGRAMS article. If ECM ground circuit is defective, repair ground circuit as necessary. If ECM ground circuit is okay, replace ECM.

Fig. 8: Locating Data Link Connector No. 3 (Camry) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 ENGINE PERFORMANCE System & Component Testing - 4-Cylinder

Fig. 11: Locating Data Link Connector No. 3 (Corolla) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 ENGINE PERFORMANCE System & Component Testing - 4-Cylinder

Fig. 17: Locating Data Link Connector No. 3 (Tacoma) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ENGINE CONTROL MODULE
Power & Ground Circuits

For testing of Engine Control Module (ECM) power and ground circuits, see ENGINE CONTROL MODULE POWER SOURCE CIRCUIT . Also see PIN VOLTAGE CHARTS article. For illustration of ECM location, see THEORY & OPERATION article. For identification of ECM electrical connector terminals. See Fig. 18 -Fig. 28 .

Fig. 18: Identifying Engine Control Module Electrical Connector Terminals (Camry) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 ENGINE PERFORMANCE System & Component Testing - 4-Cylinder

Fig. 19: Identifying Engine Control Module Electrical Connector Terminals (Camry Solara) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 20: Identifying Engine Control Module Electrical Connector Terminals (Celica) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 21: Identifying Engine Control Module Electrical Connector Terminals (Corolla With 3-Speed A/T Or M/T) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 22: Identifying Engine Control Module Electrical Connector Terminals (Corolla With 4-Speed A/T) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 ENGINE PERFORMANCE System & Component Testing - 4-Cylinder

Fig. 27: Identifying Engine Control Module Electrical Connector Terminals (RAV4) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 28: Identifying Engine Control Module Electrical Connector Terminals (Tacoma) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

ENGINE SENSORS & SWITCHES

ACCELERATOR PEDAL POSITION SENSOR
Camry & Camry Solara

1. Disconnect electrical connector at accelerator pedal position sensor. Accelerator pedal position sensor is located near top of accelerator pedal. See Fig. 29 . 2. Using ohmmeter, check that resistance is within specification between specified terminals on accelerator pedal position sensor. See ACCELERATOR PEDAL POSITION SENSOR RESISTANCE table. See Fig. 29 . Replace accelerator pedal position sensor if resistance is not within specification. See ACCELERATOR PEDAL POSITION SENSOR under ENGINE SENSORS & SWITCHES in REMOVAL, OVERHAUL & INSTALLATION - 4-CYLINDER article. ACCELERATOR PEDAL POSITION SENSOR RESISTANCE Application Terminals Ohms Camry VPA1 & EP2 5000 Or Less VPA2 & EP1 5000 Or Less VCP1 & EP1 2250-4750 VCP2 & EP2 2250-4750 (1) 2250-4750 Camry Solara VCP1 & EP1 VCP2 & EP2
(1) Resistance at 68F (20C). (1) 2250-4750

2002 ENGINE PERFORMANCE System & Component Testing - 4-Cylinder

Fig. 29: Locating & Testing Accelerator Pedal Position Sensor (Camry & Camry Solara) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
MR2 With Sequential Manual Transaxle

There are 2 types of manual transaxles used. Sequential manual transaxle may be identified by shift lever pattern which consists of "R", "N", "S" and "+" in place of the conventional type shift lever pattern and there is no clutch pedal. For testing of accelerator pedal position sensor, see THROTTLE BODY under IDLE CONTROL SYSTEMS.
Prius

WARNING: Read service precautions before proceeding with service procedure. See SERVICE PRECAUTIONS . 1. Disconnect electrical connector at accelerator pedal position sensor. Accelerator pedal position sensor is located near top of accelerator pedal. See Fig. 30 . 2. Using ohmmeter, check resistance between VCP1 and EP1 terminals, and between VCP2 and EP2 terminals on accelerator pedal position sensor. See Fig. 30 . Resistance should be 1500-6000 ohms at 68F (20C). Replace accelerator pedal position sensor if resistance is not within specification. See ACCELERATOR PEDAL POSITION SENSOR under ENGINE SENSORS & SWITCHES in REMOVAL, OVERHAUL & INSTALLATION - 4-CYLINDER article.

2002 ENGINE PERFORMANCE System & Component Testing - 4-Cylinder

Fig. 30: Locating & Testing Accelerator Pedal Position Sensor (Prius) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. A/C COMPRESSOR LOCK SENSOR
Camry, Camry Solara With Manual A/C, Celica, Highlander, MR2 & RAV4

1. Disconnect electrical connector for A/C compressor lock sensor and magnetic clutch on front of A/C compressor. This is the electrical located near front of A/C compressor. 2. Using ohmmeter, check resistance between terminals No. 1 and 2 on electrical connector for A/C compressor lock sensor and magnetic clutch. See Fig. 31 -Fig. 35 . Ensure resistance is within specification. See A/C COMPRESSOR LOCK SENSOR RESISTANCE table. Replace A/C compressor lock sensor if resistance is not within specification. It may be necessary to replace A/C compressor along with A/C compressor lock sensor as an assembly. Consult parts department for parts availability. A/C COMPRESSOR LOCK SENSOR RESISTANCE Application Ohms @ 68F (20C) Camry 165-205 Camry Solara 65-125 Celica, Highlander, MR2 & RAV4 165-205

2002 ENGINE PERFORMANCE System & Component Testing - 4-Cylinder

Fig. 35: Testing A/C Compressor Lock Sensor (RAV4) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. A/C EVAPORATOR TEMPERATURE SENSOR
Camry Solara With Manual A/C

1. Remove A/C evaporator temperature sensor. A/C evaporator temperature sensor is located in evaporator case, next to evaporator core. For servicing of A/C evaporator temperature sensor, see appropriate article in AIR CONDITIONING & HEATING. 2. Place probe end of A/C evaporator temperature sensor with thermometer in container of water. Using ohmmeter, check resistance between electrical terminals on A/C evaporator temperature sensor while using ice to cool water. Ensure ice does not contact A/C evaporator temperature sensor. 3. Check that resistance is within specification in relation to water temperature. See Fig. 36 . Replace A/C evaporator temperature sensor if resistance is not within specification at specified temperature. For servicing of A/C evaporator temperature sensor, see appropriate article in AIR CONDITIONING & HEATING.

2002 ENGINE PERFORMANCE System & Component Testing - 4-Cylinder

Fig. 36: Testing A/C Evaporator Temperature Sensor (Camry Solara With Manual A/C) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. AIR/FUEL SENSOR NOTE:
Camry

Air/Fuel (A/F) sensor may also be referred to as Air/Fuel (A/F) ratio sensor.

1. Heated A/F sensor is mounted on exhaust manifold above catalytic converter. If problem exists in A/F sensor, heater or wiring circuit, a Diagnostic Trouble Code (DTC) may be stored in Engine Control Module (ECM). See TESTING PROCEDURE under SELF-DIAGNOSTIC SYSTEM in appropriate SELF-DIAGNOSTICS article for retrieving of DTCs. 2. To test heater resistance on A/F sensor, disconnect electrical connector for A/F sensor. Using ohmmeter, check resistance between +B and HT terminals on electrical connector. See Fig. 37 . Replace A/F sensor if resistance is not within specification. See A/F SENSOR HEATER RESISTANCE table. See AIR/FUEL SENSOR under ENGINE SENSORS & SWITCHES in REMOVAL, OVERHAUL & INSTALLATION - 4-CYLINDER article. 3. To check that heater is not shorted, using ohmmeter, check that no continuity exists between E1 and HT terminals on electrical connector. See Fig. 37 . Replace A/F sensor if continuity exists. See

2002 ENGINE PERFORMANCE System & Component Testing - 4-Cylinder

AIR/FUEL SENSOR under ENGINE SENSORS & SWITCHES in REMOVAL, OVERHAUL & INSTALLATION - 4-CYLINDER article.
Camry Solara

1. Heated A/F sensor is mounted on exhaust manifold above catalytic converter. If problem exists in A/F sensor, heater or wiring circuit, a Diagnostic Trouble Code (DTC) may be stored in Engine Control Module (ECM). See TESTING PROCEDURE under SELF-DIAGNOSTIC SYSTEM in appropriate SELF-DIAGNOSTICS article for retrieving of DTCs. 2. To test heater resistance on A/F sensor, disconnect electrical connector for A/F sensor. Using ohmmeter, check resistance between +B and HT terminals on electrical connector. See Fig. 38 . Replace A/F sensor if resistance is not within specification. See A/F SENSOR HEATER RESISTANCE table. See AIR/FUEL SENSOR under ENGINE SENSORS & SWITCHES in REMOVAL, OVERHAUL & INSTALLATION - 4-CYLINDER article.
Highlander & RAV4

1. Two heated A/F sensors are used. Heated A/F sensors are mounted on exhaust manifold above catalytic converters. A/F sensor for cylinders No. 1 and 4 is referred to as bank No. 1 sensor No. 1. A/F sensor for cylinders No. 2 and 3 is referred to as bank No. 2 sensor No. 1. If problem exists in A/F sensor, heater or wiring circuit, a Diagnostic Trouble Code (DTC) may be stored in Engine Control Module (ECM). See TESTING PROCEDURE under SELF-DIAGNOSTIC SYSTEM in appropriate SELF-DIAGNOSTICS article for retrieving of DTCs. 2. To test heater resistance on A/F sensor, disconnect electrical connector for A/F sensor. Using ohmmeter, check resistance between +B and HT terminals on electrical connector. See Fig. 39 and Fig. 40 . Replace A/F sensor if resistance is not within specification. See A/F SENSOR HEATER RESISTANCE table. See AIR/FUEL SENSOR under ENGINE SENSORS & SWITCHES in REMOVAL, OVERHAUL & INSTALLATION - 4-CYLINDER article.
Tacoma

1. Heated A/F sensor is mounted on exhaust pipe in front of catalytic converter. If problem exists in A/F sensor, heater or wiring circuit, a Diagnostic Trouble Code (DTC) may be stored in Engine Control Module (ECM). See TESTING PROCEDURE under SELF-DIAGNOSTIC SYSTEM in appropriate SELF-DIAGNOSTICS article for retrieving of DTCs. 2. To test heater resistance on A/F sensor, disconnect electrical connector for A/F sensor. Using ohmmeter, check resistance between +B and HT terminals on electrical connector. See Fig. 41 . Replace A/F sensor if resistance is not within specification. See A/F SENSOR HEATER RESISTANCE table. See AIR/FUEL SENSOR under ENGINE SENSORS & SWITCHES in REMOVAL, OVERHAUL & INSTALLATION - 4-CYLINDER article. A/F SENSOR HEATER RESISTANCE Application & Temperature Ohms Camry 68F (20 1.8-3.4 C) 932F 5.0-7.5 (500C)

2002 ENGINE PERFORMANCE System & Component Testing - 4-Cylinder

Camry Solara 68F (20 C) Highlander 68F (20 C) 932F (500C) RAV4 68F (20 C) 1472F (800C) Tacoma 68F (20 C) 1472F (800C)

.8-1.4

1.8-3.4 5.0-7.5

.8-1.4 1.8-3.2

.8-1.4 1.8-3.2

2002 ENGINE PERFORMANCE System & Component Testing - 4-Cylinder

Fig. 41: Testing Heater On Air/Fuel Sensor (Tacoma) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. AIRFLOW METER NOTE: Airflow meter may also be referred to as Mass Airflow (MAF) meter. WARNING: On Prius, read service precautions before proceeding with service procedure. See SERVICE PRECAUTIONS . 1. Remove airflow meter. See AIRFLOW METER under ENGINE SENSORS & SWITCHES in REMOVAL, OVERHAUL & INSTALLATION - 4-CYLINDER article. 2. Using ohmmeter, check resistance between terminals E2 and THA on airflow meter. See Fig. 42 -Fig. 45 . Resistance should be within specification in relation to temperature. See AIRFLOW METER RESISTANCE table. Replace airflow meter if resistance is not within specification. AIRFLOW METER RESISTANCE Application & Temperature Ohms Camry -4F (-20 13,600-18,400 C)

2002 ENGINE PERFORMANCE System & Component Testing - 4-Cylinder

68F (20 C) 140F (60C) Camry Solara, Celica & ECHO -4F (-20 C) 68F (20 C) 140F (60C) Corolla -4F (-20 C) 68F (20 C) 140F (60C) Highlander -4F (-20 C) 68F (20 C) 140F (60C) MR2, Prius & RAV4 -4F (-20 C) 68F (20 C) 140F (60C) Tacoma -4F (-20 C) 32F (0 C) 68F (20 C) 104F (40C) 140F (60C) 176F (80C)

2210-2690 493-667

13,600-18,400 2210-2690 490-670

13,600-18,400 2200-2700 500-700

13,600-18,400 2210-2690 493-667

13,600-18,400 2210-2690 490-670

10,000-20,000 4000-7000 2000-3000 900-1300 400-700 200-400

3. Airflow meter operation should be checked. On Camry and Highlander, go to next step. On Camry

2002 ENGINE PERFORMANCE System & Component Testing - 4-Cylinder

Solara, Celica, Corolla, ECHO, MR2, Prius, RAV4 and Tacoma, go to step 5 . 4. Apply battery voltage to +B terminal on airflow meter and battery ground to E2G terminal on airflow meter. See Fig. 42 . Connect voltmeter leads to proper terminals on airflow meter. See Fig. 42 . Apply air into designated area on airflow meter and note voltage reading. See Fig. 42 . While air is being applied, voltage reading should fluctuate. Replace airflow meter if voltage does not fluctuate. 5. Install electrical connector on airflow meter. Connect voltmeter leads to proper terminals on airflow meter with electrical connector installed. See Fig. 46 -Fig. 48 . Turn ignition on. Apply air into designated area on airflow meter and note voltage reading. See Fig. 42 and Fig. 46 -Fig. 48 . While air is being applied, voltage reading should fluctuate. Replace airflow meter if voltage does not fluctuate. Turn ignition off. Remove voltmeter.

Fig. 42: Identifying Airflow Meter Terminals, Air Application Area & Voltmeter Connections (Camry & Highlander) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 ENGINE PERFORMANCE System & Component Testing - 4-Cylinder

Fig. 44: Testing Airflow Meter Resistance (Corolla) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 ENGINE PERFORMANCE System & Component Testing - 4-Cylinder

Fig. 47: Testing Airflow Meter Operation (Corolla) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 ENGINE PERFORMANCE System & Component Testing - 4-Cylinder

Fig. 48: Testing Airflow Meter Operation (Tacoma) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. BRAKELIGHT SWITCH NOTE: Brakelight switch may also be referred to as stoplight switch.

Camry, Camry Solara & Highlander

1. Disconnect electrical connector at brakelight switch. Brakelight switch is located near top of brake pedal. Note terminal identification on brakelight switch. See Fig. 49 . 2. Using ohmmeter, check that continuity exists between terminals No. 1 and 2 with brake pedal depressed so pin on brakelight switch is extended. Check that no continuity exists between terminals No. 1 and 2 with brake pedal released so pin on brakelight switch is pushed in. 3. Check that no continuity exists between terminals No. 3 and 4 with brake pedal depressed so pin on brakelight switch is extended. Check that continuity exists between terminals No. 3 and 4 with brake pedal released so pin on brakelight switch is pushed in. Adjust or replace brakelight switch if operation is not as described. See BRAKELIGHT SWITCH under ENGINE SENSORS & SWITCHES in REMOVAL, OVERHAUL & INSTALLATION - 4-CYLINDER article.

Fig. 49: Identifying Brakelight Switch Terminals (Camry, Camry Solara & Highlander) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Celica, Corolla, MR2, RAV4 & Tacoma

2002 ENGINE PERFORMANCE System & Component Testing - 4-Cylinder

1. Disconnect electrical connector at brakelight switch. Brakelight switch is located near top of brake pedal. Note terminal identification on brakelight switch. See Fig. 50 . 2. On models without cruise control, using ohmmeter, check that no continuity exists between terminals No. 1 and 2 with brake pedal released so pin on brakelight switch is pushed in. Check that continuity exists between terminals No. 1 and 2 with brake pedal depressed so pin on brakelight switch is extended. Adjust or replace brakelight switch if operation is not as described. See BRAKELIGHT SWITCH under ENGINE SENSORS & SWITCHES in REMOVAL, OVERHAUL & INSTALLATION - 4-CYLINDER article. 3. On models with cruise control, using ohmmeter, check that no continuity exists between terminals No. 1 and 2 with brake pedal released so pin on brakelight switch is pushed in. Check that continuity exists between terminals No. 1 and 2 with brake pedal depressed so pin on brakelight switch is extended. 4. Check that no continuity exists between terminals No. 3 and 4 with brake pedal depressed so pin on brakelight switch is extended. Check that continuity exists between terminals No. 3 and 4 with brake pedal released so pin on brakelight switch is pushed in. Adjust or replace brakelight switch if operation is not as described. See BRAKELIGHT SWITCH under ENGINE SENSORS & SWITCHES in REMOVAL, OVERHAUL & INSTALLATION - 4-CYLINDER article.

Fig. 50: Identifying Brakelight Switch Terminals (Celica, Corolla, MR2, RAV4 & Tacoma) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
ECHO

1. Disconnect electrical connector at brakelight switch. Brakelight switch is located near top of brake pedal. Note terminal identification on brakelight switch. See Fig. 51 . 2. Using ohmmeter, check that continuity exists between terminals No. 1 and 2 with brake pedal depressed so pin on brakelight switch is extended. Check that no continuity exists between terminals No. 1 and 2 with brake pedal released so pin on brakelight switch is pushed in. Adjust or replace brakelight switch if operation is not as described. See BRAKELIGHT SWITCH under ENGINE SENSORS & SWITCHES in REMOVAL, OVERHAUL & INSTALLATION - 4-CYLINDER article.

2002 ENGINE PERFORMANCE System & Component Testing - 4-Cylinder

Fig. 51: Identifying Brakelight Switch Terminals (ECHO) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. CAMSHAFT POSITION SENSOR For testing camshaft position sensor, see CAMSHAFT POSITION SENSOR under IGNITION SYSTEMS in BASIC DIAGNOSTIC PROCEDURES - 4-CYLINDER article. CRANKSHAFT POSITION SENSOR For testing crankshaft position sensor, see CRANKSHAFT POSITION SENSOR under IGNITION SYSTEMS in BASIC DIAGNOSTIC PROCEDURES - 4-CYLINDER article. EGR GAS TEMPERATURE SENSOR
Tacoma 2.7L 3RZ-FE

1. EGR gas temperature sensor is located near EGR valve. Remove EGR gas temperature sensor. See EGR GAS TEMPERATURE SENSOR under ENGINE SENSORS & SWITCHES in REMOVAL, OVERHAUL & INSTALLATION - 4-CYLINDER article. 2. Place threaded end of EGR gas temperature sensor and thermometer in container of oil. Attach ohmmeter between electrical terminals on EGR gas temperature sensor. 3. Heat oil and note resistance at specified temperature. See EGR GAS TEMPERATURE SENSOR RESISTANCE table. Replace EGR gas temperature sensor if resistance is not within specification. Reinstall EGR gas temperature sensor.

2002 ENGINE PERFORMANCE System & Component Testing - 4-Cylinder

EGR GAS TEMPERATURE SENSOR RESISTANCE Temperature 122F (50C) 212F (100C) 302F (150C) ENGINE COOLANT TEMPERATURE SENSOR
Camry, Camry Solara, Celica, Corolla & ECHO

Ohms 64,000-97,000 11,000-16,000 2000-4000

1. Ensure ignition is off. Disconnect electrical connector from Engine Coolant Temperature (ECT) sensor. See ENGINE COOLANT TEMPERATURE SENSOR LOCATION table. Remove ECT sensor. See ENGINE COOLANT TEMPERATURE SENSOR under ENGINE SENSORS & SWITCHES in REMOVAL, OVERHAUL & INSTALLATION - 4-CYLINDER article. 2. Place probe end of ECT sensor and thermometer in container of water. Attach ohmmeter between electrical terminals No. 1 and 2 on ECT sensor. See Fig. 52 and Fig. 53 . Heat water and note that resistance is within specification in relation to temperature. See Fig. 54 . Replace ECT sensor if resistance is not within specification.

Fig. 52: Identifying Engine Coolant Temperature Sensor Electrical Terminals (Camry) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 ENGINE PERFORMANCE System & Component Testing - 4-Cylinder

Fig. 53: Identifying Engine Coolant Temperature Sensor Electrical Terminals (Camry Solara, Celica, Corolla & ECHO) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 ENGINE PERFORMANCE System & Component Testing - 4-Cylinder

Fig. 54: Testing Engine Coolant Temperature Sensor Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 ENGINE PERFORMANCE System & Component Testing - 4-Cylinder

Highlander, MR2, Prius, RAV4 & Tacoma

WARNING: On Prius, read service precautions before proceeding with service procedure. See SERVICE PRECAUTIONS . 1. Ensure ignition is off. Disconnect electrical connector from Engine Coolant Temperature (ECT) sensor. See ENGINE COOLANT TEMPERATURE SENSOR LOCATION table. Remove ECT sensor. See ENGINE COOLANT TEMPERATURE SENSOR under ENGINE SENSORS & SWITCHES in REMOVAL, OVERHAUL & INSTALLATION - 4-CYLINDER article. 2. Place probe end of ECT sensor and thermometer in container of water. Attach ohmmeter between electrical terminals on ECT sensor. Heat water and note that resistance is within specification in relation to temperature. See Fig. 54 . Replace ECT sensor if resistance is not within specification. ENGINE COOLANT TEMPERATURE SENSOR LOCATION Model Location Camry & Camry On Flywheel End Of Cylinder Head & Solara Contains Dark Gray Electrical Connector With Green/Yellow & Brown Wires Celica On Flywheel End Of Cylinder Head & Contains Gray Electrical Connector With Green & Brown Wires Corolla On Flywheel End Of Cylinder Head & Contains Dark Gray Electrical Connector With White & Brown Wires ECHO On Flywheel End Of Cylinder Head & Contains Gray Electrical Connector With Red/Blue & Brown Wires Highlander On Flywheel End Of Cylinder Head & Contains Dark Gray 2-Pin Electrical Connector With White/Blue & White Wires MR2 On Flywheel End Of Cylinder Head & Contains Dark Gray 2-Pin Electrical Connector With Red/Blue & Brown Wires Prius On Flywheel End Of Cylinder Head & Contains Dark Gray 2-Pin Electrical Connector With White & Brown Wires RAV4 On Flywheel End Of Cylinder Head & Contains Dark Gray 2-Pin Electrical Connector With White & Brown Wires Tacoma On Coolant Housing At Rear Of Cylinder Head & Contains Dark Gray 2-Pin Electrical Connector With Green/Red & Blue/Black Wires HEATED OXYGEN SENSOR
Camry

2002 ENGINE PERFORMANCE System & Component Testing - 4-Cylinder

1. A heated A/F sensor is mounted on exhaust manifold above catalytic converter. For testing of A/F sensor, see AIR/FUEL SENSOR . Another heated oxygen sensor is mounted on exhaust pipe after catalytic converter. This heated oxygen sensor is referred to as bank No. 1 sensor No. 2. 2. To test heater resistance on heated oxygen sensor, disconnect electrical connector for heated oxygen sensor. Using ohmmeter, check resistance between +B and HT terminals on electrical connector. See Fig. 55 . Replace heated oxygen sensor if resistance is not 11-16 ohms at 68F (20C). See HEATED OXYGEN SENSOR under ENGINE SENSORS & SWITCHES in REMOVAL, OVERHAUL & INSTALLATION - 4-CYLINDER article. 3. To check that heater is not shorted, using ohmmeter, check that no continuity exists between E1 and HT terminals on electrical connector. See Fig. 55 . Replace heated oxygen sensor if continuity exists. See HEATED OXYGEN SENSOR under ENGINE SENSORS & SWITCHES in REMOVAL, OVERHAUL & INSTALLATION - 4-CYLINDER article. 4. If problem exists in heated oxygen sensor, heater or wiring circuit, a Diagnostic Trouble Code (DTC) may be stored in Engine Control Module (ECM). See TESTING PROCEDURE under SELFDIAGNOSTIC SYSTEM in appropriate SELF-DIAGNOSTICS article for retrieving of DTCs.

Fig. 55: Identifying Terminals On Electrical Connector For Heated Oxygen Sensor (Camry) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Camry Solara

1. A heated A/F sensor is mounted on exhaust manifold above catalytic converter. For testing of A/F

2002 ENGINE PERFORMANCE System & Component Testing - 4-Cylinder

sensor, see AIR/FUEL SENSOR . Another heated oxygen sensor is mounted on exhaust pipe after catalytic converter. This heated oxygen sensor is referred to as bank No. 1 sensor No. 2. 2. To test heater resistance on heated oxygen sensor, disconnect electrical connector for heated oxygen sensor. Using ohmmeter, check resistance between +B and HT terminals on electrical connector. See Fig. 56 . Replace heated oxygen sensor if resistance is not 11-16 ohms at 68F (20C). See HEATED OXYGEN SENSOR under ENGINE SENSORS & SWITCHES in REMOVAL, OVERHAUL & INSTALLATION - 4-CYLINDER article. 3. If problem exists in heated oxygen sensor, heater or wiring circuit, a Diagnostic Trouble Code (DTC) may be stored in Engine Control Module (ECM). See TESTING PROCEDURE under SELFDIAGNOSTIC SYSTEM in appropriate SELF-DIAGNOSTICS article for retrieving of DTCs.

Fig. 56: Locating Electrical Connector & Testing Heated Oxygen Sensor Bank No. 1 Sensor No. 2 (Camry Solara) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Celica

1. Two heated oxygen sensors are used. One heated oxygen sensor is mounted on exhaust pipe in front of front catalytic converter. This heated oxygen sensor is referred to as bank No. 1 sensor No. 1, or front oxygen sensor. Another heated oxygen sensor is mounted on exhaust pipe behind catalytic converter. This heated oxygen sensor is referred to as bank No. 1 sensor No. 2, or rear oxygen sensor. 2. To test heater resistance on heated oxygen sensor, disconnect electrical connector for appropriate heated oxygen sensor. Electrical connector for bank No. 1 sensor No. 1 is a 4-pin electrical connector located near front of center console. See Fig. 57 . Electrical connector for bank No. 1 sensor No. 2 is a Gray 4-pin electrical connector located below passenger's side front seat and carpet, near center console. See Fig. 58 .

2002 ENGINE PERFORMANCE System & Component Testing - 4-Cylinder

3. Using ohmmeter, check resistance between +B and HT terminals on electrical connector. See Fig. 57 and Fig. 58 . Replace heated oxygen sensor if resistance is not 11-16 ohms at 68F (20C). See HEATED OXYGEN SENSOR under ENGINE SENSORS & SWITCHES in REMOVAL, OVERHAUL & INSTALLATION - 4-CYLINDER article. 4. If problem exists with either heated oxygen sensor, heater or wiring circuit, a Diagnostic Trouble Code (DTC) may be stored in Engine Control Module (ECM). See TESTING PROCEDURE under SELF-DIAGNOSTIC SYSTEM in appropriate SELF-DIAGNOSTICS article for retrieving of DTCs.

Fig. 57: Locating Electrical Connector & Testing Heated Oxygen Sensor Bank No. 1 Sensor No. 1 (Celica) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 ENGINE PERFORMANCE System & Component Testing - 4-Cylinder

Fig. 58: Locating Electrical Connector & Testing Heated Oxygen Sensor Bank No. 1 Sensor No. 2 (Celica) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Corolla

1. A heated oxygen sensor is mounted on exhaust pipe in front of catalytic converter. This heated oxygen sensor is referred to as bank No. 1 sensor No. 1, or front oxygen sensor. Another heated oxygen sensor is mounted on exhaust pipe behind catalytic converter. This heated oxygen sensor is referred to as bank No. 1 sensor No. 2, or rear oxygen sensor. 2. To test heater resistance on heated oxygen sensor, disconnect electrical connector for appropriate heated oxygen sensor. Electrical connector for bank No. 1 sensor No. 1 is a Dark Gray 4-pin electrical connector located near exhaust manifold. See Fig. 59 . Electrical connector for bank No. 1 sensor No. 2 is a Dark Gray 4-pin electrical connector located below passenger's side front seat and carpet, near center console. See Fig. 60 . 3. Using ohmmeter, check resistance between +B and HT terminals on electrical connector. See Fig. 59 and Fig. 60 . Replace heated oxygen sensor if resistance is not 11-16 ohms at 68F (20C) and 23-32 ohms at 1472F (800C). See HEATED OXYGEN SENSOR under ENGINE SENSORS & SWITCHES in REMOVAL, OVERHAUL & INSTALLATION - 4-CYLINDER article. 4. If problem exists with either heated oxygen sensor, heater or wiring circuit, a Diagnostic Trouble Code (DTC) may be stored in Engine Control Module (ECM). See TESTING PROCEDURE under SELF-DIAGNOSTIC SYSTEM in appropriate SELF-DIAGNOSTICS article for retrieving of DTCs.

2002 ENGINE PERFORMANCE System & Component Testing - 4-Cylinder

Fig. 59: Locating Electrical Connector & Testing Heated Oxygen Sensor Bank No. 1 Sensor No. 1 (Corolla) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 ENGINE PERFORMANCE System & Component Testing - 4-Cylinder

Fig. 60: Locating Electrical Connector & Testing Heated Oxygen Sensor Bank No. 1 Sensor No. 2 (Corolla) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
ECHO

1. A heated oxygen sensor is mounted on exhaust pipe in front of catalytic converter. This heated oxygen sensor is referred to as bank No. 1 sensor No. 1, or front oxygen sensor. Another heated oxygen sensor is mounted on exhaust pipe behind catalytic converter. This heated oxygen sensor is referred to as bank No. 1 sensor No. 2, or rear oxygen sensor. 2. To test heater resistance on heated oxygen sensor, disconnect electrical connector for appropriate heated oxygen sensor. Electrical connector for bank No. 1 sensor No. 1 is a Gray 4-pin electrical connector located near exhaust pipe. See Fig. 61 . Electrical connector for bank No. 1 sensor No. 2 is a Gray 4-pin electrical connector located below passenger's side front seat and carpet, near center console. See Fig. 62 . 3. Using ohmmeter, check resistance between +B and HT terminals on electrical connector. See Fig. 61 and Fig. 62 . Replace heated oxygen sensor if resistance is not 11-16 ohms at 68F (20C). See HEATED OXYGEN SENSOR under ENGINE SENSORS & SWITCHES in REMOVAL, OVERHAUL & INSTALLATION - 4-CYLINDER article. 4. If problem exists with either heated oxygen sensor, heater or wiring circuit, a Diagnostic Trouble Code (DTC) may be stored in Engine Control Module (ECM). See TESTING PROCEDURE under SELF-DIAGNOSTIC SYSTEM in appropriate SELF-DIAGNOSTICS article for retrieving of DTCs.

2002 ENGINE PERFORMANCE System & Component Testing - 4-Cylinder

Fig. 62: Locating Electrical Connector & Testing Heated Oxygen Sensor Bank No. 1 Sensor No. 2 (ECHO) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Highlander

1. Two heated Air/Fuel (A/F) sensors are used. Heated A/F sensors are mounted on exhaust manifold above catalytic converter. For testing of A/F sensors, see AIR/FUEL SENSOR . Two heated oxygen sensors are also used. Heated oxygen sensors are mounted on exhaust manifold below catalytic converters. Heated oxygen sensor for cylinders No. 1 and 4 is referred to as bank No. 1 sensor No. 2. Heated oxygen sensor for cylinders No. 2 and 3 is referred to as bank No. 2 sensor No. 2. 2. To test heater resistance on heated oxygen sensor, disconnect electrical connector for heated oxygen sensor. Using ohmmeter, check resistance between +B and HT terminals on electrical connector. See Fig. 63 . Replace heated oxygen sensor if resistance is not 11-16 ohms at 68F (20C). See HEATED OXYGEN SENSOR under ENGINE SENSORS & SWITCHES in REMOVAL, OVERHAUL & INSTALLATION - 4-CYLINDER article. 3. If problem exists in either heated oxygen sensor, heater or wiring circuit, a Diagnostic Trouble Code (DTC) may be stored in Engine Control Module (ECM). See TESTING PROCEDURE under SELFDIAGNOSTIC SYSTEM in appropriate SELF-DIAGNOSTICS article for retrieving of DTCs.

2002 ENGINE PERFORMANCE System & Component Testing - 4-Cylinder

Fig. 63: Identifying Terminals On Electrical Connector For Heated Oxygen Sensor (Highlander) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
MR2

1. Three heated oxygen sensors are used with 2 being mounted on exhaust manifold, above catalytic converters, and one on exhaust pipe behind catalytic converters. Heated oxygen sensor for cylinders No. 1 and 4 is referred to as bank No. 1 sensor No. 1. Heated oxygen sensor for cylinders No. 2 and 3 is referred to as bank No. 2 sensor No. 1. Heated oxygen sensor mounted on exhaust pipe is referred to as bank No. 1 sensor No. 2. 2. To test heater resistance on heated oxygen sensor, disconnect electrical connector for appropriate heated oxygen sensor. See Fig. 64 -Fig. 66 . Using ohmmeter, check resistance between +B and HT terminals on electrical connector. See Fig. 64 -Fig. 66 . Replace heated oxygen sensor if resistance is not 11-16 ohms at 68F (20C) and 23-32 ohms at 1472F (800C). See HEATED OXYGEN SENSOR under ENGINE SENSORS & SWITCHES in REMOVAL, OVERHAUL & INSTALLATION - 4-CYLINDER article. 3. If problem exists with any heated oxygen sensor, heater or wiring circuit, a Diagnostic Trouble Code (DTC) may be stored in Engine Control Module (ECM). See TESTING PROCEDURE under SELFDIAGNOSTIC SYSTEM in appropriate SELF-DIAGNOSTICS article for retrieving of DTCs.

2002 ENGINE PERFORMANCE System & Component Testing - 4-Cylinder

Fig. 66: Locating Electrical Connector & Testing Heated Oxygen Sensor Bank No. 1 Sensor No. 2 (MR2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Prius

WARNING: Read service precautions before proceeding with service procedure. See SERVICE PRECAUTIONS . 1. A heated oxygen sensor is mounted on exhaust pipe in front of catalytic converter. This heated oxygen sensor is referred to as bank No. 1 sensor No. 1, or front oxygen sensor. Another heated oxygen sensor is mounted on exhaust pipe behind catalytic converter. This heated oxygen sensor is referred to as bank No. 1 sensor No. 2, or rear oxygen sensor. 2. To test heater resistance on heated oxygen sensor, disconnect electrical connector for appropriate heated oxygen sensor. Electrical connector for bank No. 1 sensor No. 1 is a Dark Gray 4-pin electrical connector located near exhaust manifold. See Fig. 67 . Electrical connector for bank No. 1 sensor No. 2 is a Dark Gray 4-pin electrical connector located below passenger's side carpet, near center console. See Fig. 68 . 3. Using ohmmeter, check resistance between +B and HT terminals on electrical connector. See Fig. 67 and Fig. 68 . Replace heated oxygen sensor if resistance is not 11-16 ohms at 68F (20C). See HEATED OXYGEN SENSOR under ENGINE SENSORS & SWITCHES in REMOVAL, OVERHAUL & INSTALLATION - 4-CYLINDER article. 4. If problem exists with either heated oxygen sensor, heater or wiring circuit, a Diagnostic Trouble Code (DTC) may be stored in Engine Control Module (ECM). See TESTING PROCEDURE under

2002 ENGINE PERFORMANCE System & Component Testing - 4-Cylinder

Fig. 68: Locating Electrical Connector & Testing Heated Oxygen Sensor Bank No. 1 Sensor No. 2 (Prius) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
RAV4

1. Two heated Air/Fuel (A/F) sensors are used. Heated A/F sensors are mounted on exhaust manifold above catalytic converter. For testing of A/F sensors, see AIR/FUEL SENSOR . Two heated oxygen sensors are also used. Heated oxygen sensors are mounted on exhaust manifold below catalytic converters. Heated oxygen sensor for cylinders No. 1 and 4 is referred to as bank No. 1 sensor No. 2. Heated oxygen sensor for cylinders No. 2 and 3 is referred to as bank No. 2 sensor No. 2. 2. To test heater resistance on heated oxygen sensor, disconnect electrical connector for heated oxygen sensor. See Fig. 69 and Fig. 70 . Using ohmmeter, check resistance between +B and HT terminals on electrical connector. See Fig. 69 and Fig. 70 . Replace heated oxygen sensor if resistance is not 11-16 ohms at 68F (20C) and 23-32 ohms at 1472F (800C). See HEATED OXYGEN SENSOR under ENGINE SENSORS & SWITCHES in REMOVAL, OVERHAUL & INSTALLATION - 4CYLINDER article. 3. If problem exists in either heated oxygen sensor, heater or wiring circuit, a Diagnostic Trouble Code (DTC) may be stored in Engine Control Module (ECM). See TESTING PROCEDURE under SELFDIAGNOSTIC SYSTEM in appropriate SELF-DIAGNOSTICS article for retrieving of DTCs.

2002 ENGINE PERFORMANCE System & Component Testing - 4-Cylinder

Fig. 70: Locating Electrical Connector & Testing Heated Oxygen Sensor Bank No. 2 Sensor No. 2 (RAV4) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Tacoma

1. A heated Air/Fuel (A/F) sensor is mounted on exhaust pipe in front of catalytic converter. For testing of A/F sensor, see AIR/FUEL SENSOR . A heated oxygen sensor is mounted on exhaust pipe behind catalytic converter. This oxygen sensor is referred to as bank No. 1 sensor No. 2, or rear oxygen sensor. 2. To test heater resistance on heated oxygen sensor, disconnect electrical connector for heated oxygen sensor. Using ohmmeter, check resistance between +B and HT terminals on electrical connector. See Fig. 71 . Replace heated oxygen sensor if resistance is not 11-16 ohms at 68F (20C) and 23-32 ohms at 1472F (800C). See HEATED OXYGEN SENSOR under ENGINE SENSORS & SWITCHES in REMOVAL, OVERHAUL & INSTALLATION - 4-CYLINDER article. 3. If problem exists in either heated oxygen sensor, heater or wiring circuit, a Diagnostic Trouble Code (DTC) may be stored in Engine Control Module (ECM). See TESTING PROCEDURE under SELFDIAGNOSTIC SYSTEM in appropriate SELF-DIAGNOSTICS article for retrieving of DTCs.

2002 ENGINE PERFORMANCE System & Component Testing - 4-Cylinder

Fig. 71: Locating Electrical Connector & Testing Heated Oxygen Sensor Bank No. 1 Sensor No. 2 (Tacoma) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. IGNITION SWITCH 1. Disconnect electrical connector from ignition switch on bottom of upper steering column bracket. See Fig. 72 . Note ignition switch electrical terminals and ignition lock cylinder positions. See Fig. 73 Fig. 75 . 2. Using ohmmeter, check that continuity is as specified between indicated ignition switch electrical terminals in relation to ignition lock cylinder position. See IGNITION SWITCH CONTINUITY table. Replace ignition switch if defective. See IGNITION SWITCH under ENGINE SENSORS & SWITCHES in REMOVAL, OVERHAUL & INSTALLATION - 4-CYLINDER article. IGNITION SWITCH CONTINUITY Ign. Lock Cylinder Ign. Switch Application Position Terminals (1) Camry, Camry LOCK Solara & Corolla, Prius & Tacoma

Specification
(1)

2002 ENGINE PERFORMANCE System & Component Testing - 4-Cylinder

ACC ON START

2&3 2, 3 & 4; 6 & 7 1, 2 & 4; 6, 7 &8

Continuity Continuity Continuity

(1)

(1) Celica, ECHO, LOCK Highlander, MR2 & RAV4 ACC 1&3 ON 1, 2 & 3; 5 & 6 START 1 & 2; 4, 5 & 6 (1) There should be no continuity between any terminals.

Continuity Continuity Continuity

Fig. 72: Locating Typical Ignition Switch Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

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Fig. 73: Identifying Ignition Switch Electrical Terminals & Ignition Lock Cylinder Positions (Camry, Camry Solara, Corolla & Prius) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 ENGINE PERFORMANCE System & Component Testing - 4-Cylinder

Fig. 74: Identifying Ignition Switch Electrical Terminals & Ignition Lock Cylinder Positions (Celica, ECHO, Highlander, MR2 & RAV4) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 75: Identifying Ignition Switch Electrical Terminals & Ignition Lock Cylinder Positions (Tacoma) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INTAKE AIR TEMPERATURE SENSOR Intake air temperature sensor is incorporated with airflow meter. See AIRFLOW METER . KNOCK SENSOR NOTE: Knock sensor may also be referred to as knock sensor No. 1.

Camry, Camry Solara, Celica 1.8L 1ZZ-FE, Corolla, ECHO, Highlander, MR2, Prius, RAV4 & Tacoma

1. Knock sensor is located on side of cylinder block. Manufacturer recommends removing knock sensor from cylinder block before testing. See KNOCK SENSOR under ENGINE SENSORS & SWITCHES in REMOVAL, OVERHAUL & INSTALLATION - 4-CYLINDER article. 2. Using ohmmeter, check that no continuity exists between electrical terminal on knock sensor and body of knock sensor. Replace knock sensor if continuity exists.

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Celica 1.8L 2ZZ-GE

1. Knock sensor is located on side of cylinder block. Manufacturer recommends removing knock sensor from cylinder block before testing. See KNOCK SENSOR under ENGINE SENSORS & SWITCHES in REMOVAL, OVERHAUL & INSTALLATION - 4-CYLINDER article. 2. Using ohmmeter, check resistance between electrical terminals on knock sensor. Replace knock sensor if resistance is no 120,000-280,000 ohms at 68F (20C). PARK/NEUTRAL POSITION SWITCH
Camry, Camry Solara, Celica, Corolla, ECHO, Highlander, RAV4 & Tacoma

NOTE:

Park/Neutral Position (PNP) switch is used only on A/T models.

1. Disconnect electrical connector from Park/Neutral Position (PNP) switch. PNP switch is mounted on side of transmission/transaxle. Note terminal identification. See Fig. 76 -Fig. 79 . 2. Using ohmmeter, check for continuity between specified terminals with shift lever in proper positions. See PARK/NEUTRAL POSITION SWITCH SPECIFICATIONS table. 3. If proper continuity does not exist, adjust or replace PNP switch as necessary. For adjustment or replacement of PNP switch, see PARK/NEUTRAL POSITION SWITCH under ENGINE SENSORS & SWITCHES in REMOVAL, OVERHAUL & INSTALLATION - 4-CYLINDER article. PARK/NEUTRAL POSITION SWITCH SPECIFICATIONS Application & Shift Lever Position Camry Park Reverse Neutral Drive 2 Low Camry Solara, Celica, Corolla, Highlander & RAV4 Park Reverse Neutral Drive 2 Low ECHO Park Reverse Neutral Drive 2 Continuity Between Terminals No. 1 & 3; 6 & 9 2&3 3 & 5; 6 & 9 3&7 3&4 3&8 1 & 3; 6 & 9 2&3 3 & 5; 6 & 9 3&7 3&4 3&8 3 & 5; 6 & 9 2&3 1 & 3; 6 & 9 3&7 3&4

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Low Tacoma With A44D Transmission Park Reverse Neutral Drive 2 Low With A340E Or A340F Transmission Park Reverse Neutral Drive 2 Low

3&8

4 & 7; 5 & 6 4&8 4 & 10; 5 & 6 4&9 2&4 3&4 1 & 3; 6 & 9 2&3 3 & 5; 6 & 9 3&7 3&4 3&8

Fig. 76: Identifying Park/Neutral Position Switch Terminals (Camry) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

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Fig. 77: Identifying Park/Neutral Position Switch Terminals (Camry Solara, Celica With 1.8L 2ZZGE, Corolla, RAV4 & Tacoma With A340E Or A340F Transmission) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 ENGINE PERFORMANCE System & Component Testing - 4-Cylinder

Fig. 79: Identifying Park/Neutral Position Switch Terminals (Tacoma With A44D Transmission) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. POSITIVE TEMPERATURE COEFFICIENT HEATER
ECHO

1. Remove Positive Temperature Coefficient (PTC) heater along with heater core. See appropriate HEATER SYSTEMS article in AIR CONDITIONING & HEATING. 2. To test PTC heater for continuity, using ohmmeter, check that continuity exists between each electrical terminal and ground terminal on PTC heater. See Fig. 80 . Replace PTC heater if continuity does not exist between any electrical terminal and ground terminal. 3. To test PTC heater resistance, remove PTC heater from heater core. Place probe end of PTC heater and thermometer in container of water. Attach ohmmeter between electrical terminals on PTC heater. 4. Heat water and note that resistance is within specification in relation to temperature. See PTC HEATER RESISTANCE table. Replace PTC heater if resistance is not within specification. PTC HEATER RESISTANCE Temperature 77F (25C) 104F (40C) 212F (100C)

Ohms 4800-5200 2550-2850 260-340

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Fig. 80: Checking PTC Heater Continuity (ECHO) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. POWER STEERING PRESSURE SENSOR NOTE: Power steering pressure sensor may also be referred to as power steering oil pressure sensor.

ECHO

Power steering pressure sensor is located on side of power steering pump. Testing information is not available from manufacturer. If problem exists with power steering pressure sensor, a Diagnostic Trouble Code (DTC) may be stored in Engine Control Module (ECM). See TESTING PROCEDURE under SELFDIAGNOSTIC SYSTEM in appropriate SELF-DIAGNOSTICS article for retrieving of DTCs. POWER STEERING PRESSURE SWITCH NOTE: Power steering pressure switch may also be referred to as power steering oil pressure switch.

2002 ENGINE PERFORMANCE System & Component Testing - 4-Cylinder

Camry, Camry Solara, Celica, Corolla, RAV4 & Tacoma

Power steering pressure switch is located on power steering pump or near pressure hose at power steering pump. Testing information is not available from manufacturer.
Highlander

1. Remove glove box for access to Engine Control Module (ECM). For illustration of ECM location, see THEORY & OPERATION article. Note ECM electrical connector terminals. See Fig. 24 . 2. Start engine and allow engine to idle. Using voltmeter, check voltage between terminals No. 11 (Green/Yellow wire) at ECM electrical connector E7 and No. 17 (Brown wire) at ECM electrical connector E8. This is the PSW and E1 terminals at ECM. Check voltage with steering wheel at stationary position with engine idling, and while turning steering wheel with engine idling. Voltage should be 9-14 volts with steering wheel at stationary position and 0-3 volts while turning the steering wheel. If voltage is within specification, test is complete. If voltage is not within specification, go to next step. 3. Check wiring harness and electrical connectors between ECM and power steering pressure switch. See WIRING DIAGRAMS article. Power steering pressure switch is located on power steering pump. If wiring harness or electrical connector is defective, repair as necessary. If wiring harness and electrical connectors are okay, replace power steering pressure switch. See POWER STEERING PRESSURE SWITCH under ENGINE SENSORS & SWITCHES in REMOVAL, OVERHAUL & INSTALLATION - 4-CYLINDER article. THROTTLE POSITION SENSOR
Camry & Camry Solara

For testing of throttle position sensor, see THROTTLE BODY under IDLE CONTROL SYSTEMS.
Celica, Corolla, ECHO, Highlander, RAV4 & Tacoma

1. Ensure ignition is off. Disconnect electrical connector from Throttle Position (TP) sensor on throttle body. Note terminal identification on TP sensor. See Fig. 81 -Fig. 87 . 2. On Tacoma, disconnect vacuum hose and apply vacuum to throttle opener. See Fig. 87 . On all models, using ohmmeter, check resistance between specified terminals in relation to throttle position. See THROTTLE POSITION SENSOR RESISTANCE table. Replace components as necessary if resistance is not within specification.
MR2

1. There are 2 types of throttle bodies and TP sensors used depending on type of transaxle used. On models with a standard type manual transaxle, the driver operates the clutch and shifts the transaxle. On models with sequential manual transaxle, the transaxle is electronically controlled and the clutch is operated and transaxle is shifted hydraulically by moving the shift lever forward or backward. Sequential manual transaxle may be identified by shift lever pattern which consists of "R", "N", "S" and "+" in place of the conventional type shift lever pattern and no clutch pedal is used. 2. For models with standard type manual transaxle, go to next step. For models with sequential manual transaxle, see THROTTLE BODY under IDLE CONTROL SYSTEMS for testing of TP sensor. 3. Ensure ignition is off. Disconnect electrical connector from TP sensor on throttle body. Note terminal identification on TP sensor. See Fig. 85 .

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4. Using ohmmeter, check resistance between specified terminals in relation to throttle position. See THROTTLE POSITION SENSOR RESISTANCE table. Replace components as necessary if resistance is not within specification.
Prius

For testing of throttle position sensor, see THROTTLE BODY under IDLE CONTROL SYSTEMS. THROTTLE POSITION SENSOR RESISTANCE Application Throttle Position Terminals Celica, Corolla & Fully Closed VTA & E2 ECHO Fully Open VTA & E2 VC & E2 Highlander Fully Closed VTA & E2 Fully Open VTA & E2 VC & E2 MR2 & RAV4 Fully Closed VTA & E2 Fully Open VTA & E2 VC & E2 (1) Fully Closed VTA & E2 Tacoma VTA & E2 VC & E2 (1) Apply vacuum to throttle opener before checking TP sensor. Fully Open

Ohms 200-5700 2000-10,200 2500-5900 200-5700 2000-10,200 2500-5000 200-5700 2000-10,200 2500-5900 200-5700 2000-10,200 2500-5900

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Fig. 81: Identifying Throttle Position Sensor Terminals (Celica) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

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Fig. 82: Identifying Throttle Position Sensor Terminals (Corolla) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 83: Identifying Throttle Position Sensor Terminals (ECHO) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

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VACUUM SENSOR FOR HYDROCARBON ADSORBER CATALYST SYSTEM

Prius

NOTE:

Hydrocarbon adsorber catalyst system may also be referred to as HCAC system. WARNING: Read service precautions before proceeding with service procedure. See SERVICE PRECAUTIONS .

1. Ensure ignition is off. To test vacuum sensor supply voltage, disconnect electrical connector from vacuum sensor. Vacuum sensor is located at passenger's side front corner of engine and contains Black 3-pin electrical connector with Brown, Violet/White and Yellow/Red wires. See Fig. 88 . 2. Turn ignition on. Using voltmeter, check vacuum sensor supply voltage between terminals E2 and VC on wiring harness side of electrical connector for vacuum sensor. See Fig. 89 . E2 and VC terminals are the 2 outer terminals. DO NOT use center terminal. 3. Vacuum sensor supply voltage should be 4.5-5.5 volts. If vacuum sensor supply voltage is not within specification, check wiring circuit. See WIRING DIAGRAMS article. If vacuum sensor supply voltage is within specification, turn ignition off. Reinstall electrical connector on vacuum sensor. 4. To test vacuum sensor output voltage, disconnect vacuum hose from vacuum sensor. Remove glove box for access to Engine Control Module (ECM). For illustration of ECM location, see THEORY & OPERATION article. 5. Note ECM electrical connector terminals. See Fig. 26 . Connect voltmeter between terminals No. 14 (Violet/White wire) at ECM electrical connector E9 and No. 18 (Brown wire) at ECM electrical connector E8. See Fig. 26 . This is the HCLS and E1 terminals at ECM. 6. Turn ignition on. Measure and record vacuum sensor output voltage under ambient atmospheric pressure. Attach vacuum pump to bottom of vacuum sensor. Apply vacuum in specified increments and measure vacuum sensor output voltage drop at each increment. See VACUUM SENSOR OUTPUT VOLTAGE DROP SPECIFICATIONS table. Turn ignition off. Replace vacuum sensor if vacuum sensor output voltage drop is not within specification. VACUUM SENSOR OUTPUT VOLTAGE DROP SPECIFICATIONS Applied Vacuum - In. Hg Voltage Drop 3.94 .3-.5 7.87 .7-.9 11.81 1.1-1.3 15.75 1.5-1.7 19.69 1.9-2.1

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Fig. 89: Checking Vacuum Sensor Supply Voltage (Prius) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. VAPOR PRESSURE SENSOR See VAPOR PRESSURE SENSOR under FUEL EVAPORATIVE SYSTEM under EMISSION SYSTEMS & SUB-SYSTEMS. VARIABLE VALVE TIMING SENSOR NOTE: Variable Valve Timing (VVT) sensor may also be referred to as camshaft position sensor.

Camry, Camry Solara, Celica, Corolla, ECHO, Highlander, MR2, Prius & RAV4

For Variable Valve Timing (VVT) sensor testing, see CAMSHAFT POSITION SENSOR under IGNITION SYSTEMS in BASIC DIAGNOSTIC PROCEDURES - 4-CYLINDER article. VEHICLE SPEED SENSOR
Camry

1. Vehicle speed sensor is mounted on transaxle and contains a 3-pin electrical connector. See Fig. 90 .

2002 ENGINE PERFORMANCE System & Component Testing - 4-Cylinder

Raise and support vehicle so one front wheel is off the ground. Place transaxle in Neutral. 2. Turn ignition on. Using voltmeter, check voltage between terminals No. 2 and 3 on vehicle speed sensor while rotating the front wheel with electrical connector installed on vehicle speed sensor. See Fig. 91 . Voltage should change from zero volts to 10-14 volts several times while rotating the front wheel. If voltage is not as specified, it may be necessary to verify that battery voltage exists at terminal No. 1 on vehicle speed sensor. If battery voltage exists, replace vehicle speed sensor. See VEHICLE SPEED SENSOR under ENGINE SENSORS & SWITCHES in REMOVAL, OVERHAUL & INSTALLATION - 4-CYLINDER article. If battery voltage does not exist, check wiring circuit to electrical terminal No. 1 on vehicle speed sensor. See WIRING DIAGRAMS article. If necessary to check GAUGE No. 1 fuse, this fuse is located is located in fuse/relay box behind driver's side of instrument panel.

Fig. 90: Locating Typical Vehicle Speed Sensor (Camry, Camry Solara, Celica, Corolla & ECHO) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

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Fig. 91: Identifying Terminals On Vehicle Speed Sensor (Camry) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Camry Solara, Celica, Corolla & ECHO

1. Vehicle speed sensor is mounted on transaxle and contains a 3-pin electrical connector. See Fig. 90 . Remove vehicle speed sensor. Connect voltmeter positive lead to terminal No. 3 (outer terminal) and negative lead to terminal No. 2 (center terminal) on vehicle speed sensor. See Fig. 92 and Fig. 93 .

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2. Using jumper wires, connect positive battery terminal to terminal No. 1 (outer terminal) and negative battery terminal to terminal No. 2 (center terminal) on vehicle speed sensor. See Fig. 92 and Fig. 93 . 3. While rotating vehicle speed sensor shaft, ensure voltage changes from zero volts to at least 11 volts. Voltage should change 4 times per revolution of shaft. Replace vehicle speed sensor if voltage does not change as specified. See VEHICLE SPEED SENSOR under ENGINE SENSORS & SWITCHES in REMOVAL, OVERHAUL & INSTALLATION - 4-CYLINDER article.

Fig. 92: Testing Vehicle Speed Sensor (Camry Solara & ECHO) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

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Fig. 93: Testing Vehicle Speed Sensor (Celica, Corolla & Tacoma 4WD) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Highlander

Wheel speed sensors on each wheel deliver an input signal to skid control Electronic Control Unit (ECU). Skid control ECU converts input signals from wheel speed sensors to a 4-pulse input signal to the instrument cluster. Instrument cluster then converts 4-pulse input signal to a rectangular waveform and then sends vehicle speed signal to Engine Control Module (ECM). If problem exists with vehicle speed signal, a Diagnostic Trouble Code (DTC) may be stored in Engine Control Module (ECM). See TESTING PROCEDURE under SELF-DIAGNOSTIC SYSTEM in appropriate SELF-DIAGNOSTICS article for retrieving of DTCs.
MR2

Wheel speed sensors on each wheel deliver an input signal to Anti-Lock Brake System (ABS) Electronic Control Unit (ECU). ABS ECU converts input signals from wheel speed sensors to a 4-pulse input signal to the instrument cluster. Instrument cluster then converts 4-pulse input signal to a rectangular waveform and then sends vehicle speed signal to Engine Control Module (ECM). If problem exists with vehicle speed signal, a Diagnostic Trouble Code (DTC) may be stored in Engine Control Module (ECM). See TESTING PROCEDURE under SELF-DIAGNOSTIC SYSTEM in appropriate SELF-DIAGNOSTICS article for retrieving of DTCs.

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Prius

Wheel speed sensors on each wheel deliver an input signal to brake Electronic Control Unit (ECU) for the Anti-Lock Brake System (ABS). Brake ECU converts input signals from wheel speed sensors to a 4-pulse input signal to the instrument cluster. Instrument cluster then converts 4-pulse input signal to a rectangular waveform and then sends vehicle speed signal to Engine Control Module (ECM). If problem exists with vehicle speed signal, a Diagnostic Trouble Code (DTC) may be stored in Engine Control Module (ECM). See TESTING PROCEDURE under SELF-DIAGNOSTIC SYSTEM in appropriate SELF-DIAGNOSTICS article for retrieving of DTCs.
RAV4

Vehicle speed sensor is mounted on transaxle. Testing information is not available from manufacturer. If problem exists with vehicle speed sensor, a Diagnostic Trouble Code (DTC) may be stored in Engine Control Module (ECM). See TESTING PROCEDURE under SELF-DIAGNOSTIC SYSTEM in appropriate SELF-DIAGNOSTICS article for retrieving of DTCs.
Tacoma

1. Vehicle speed sensor is mounted near rear of transmission or transfer case and contains a 3-pin electrical connector. See Fig. 94 . Electrical connector contains Blue, Green/Red and Pink wires. 2. Remove vehicle speed sensor. Connect voltmeter positive lead to terminal No. 3 (outer terminal) and negative lead to terminal No. 2 (center terminal) on vehicle speed sensor. See Fig. 93 , Fig. 95 and Fig. 96 . 3. Using jumper wires, connect positive battery terminal to terminal No. 1 (outer terminal) and negative battery terminal to terminal No. 2 (center terminal) on vehicle speed sensor. See Fig. 93 , Fig. 95 and Fig. 96 . 4. While rotating vehicle speed sensor shaft, ensure voltage changes from zero volts to at least 11 volts. Voltage should change 4 times per revolution of shaft. Replace vehicle speed sensor if voltage does not change as specified. See VEHICLE SPEED SENSOR under ENGINE SENSORS & SWITCHES in REMOVAL, OVERHAUL & INSTALLATION - 4-CYLINDER article.

2002 ENGINE PERFORMANCE System & Component Testing - 4-Cylinder

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

MODULES, MOTORS, RELAYS & SOLENOIDS

THROTTLE CONTROL MOTOR NOTE: On MR2, there are 2 types of manual transaxles used. Sequential manual transaxle may be identified by shift lever pattern which consists of "R", "N", "S" and "+" in place of the conventional type shift lever pattern and there is no clutch pedal.

Camry, Camry Solara, MR2 With Sequential Manual Transaxle & Prius

For testing of throttle control motor, see THROTTLE BODY under IDLE CONTROL SYSTEMS. A/C COMPRESSOR CLUTCH RELAY NOTE: A/C compressor clutch relay may also be referred to as A/C compressor relay or magnetic clutch relay.

MR2

1. Remove A/C compressor clutch relay from relay box on firewall at driver's side front corner of engine compartment. See Fig. 105 . 2. To test A/C compressor clutch relay continuity, using ohmmeter, check for continuity and no continuity between specified terminals on A/C compressor clutch relay. See Fig. 97 . 3. To test A/C compressor clutch relay operation, apply battery voltage and ground to A/C compressor clutch relay. Using ohmmeter, check for continuity between specified terminals on A/C compressor clutch relay. See Fig. 97 . Replace A/C compressor clutch relay if defective.

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A/F HEATER RELAY NOTE: A/F heater relay may also be referred to as A/F HTR relay, A/F sensor relay or A/F relay.

Highlander

1. Remove A/F heater relay from fuse/relay box at driver's side front corner of engine compartment, just in front of strut tower. To test A/F heater relay continuity, using ohmmeter, check for continuity and no continuity between specified terminals on A/F heater relay. See Fig. 98 . 2. To test A/F heater relay operation, apply battery voltage and ground to A/F heater relay. Using ohmmeter, check for continuity between specified terminals on A/F heater relay. See Fig. 98 . Replace A/F heater relay if defective.

2002 ENGINE PERFORMANCE System & Component Testing - 4-Cylinder

1. Remove A/F heater relay from fuse/relay box at driver's side front corner of engine compartment. To test A/F heater relay continuity, using ohmmeter, check for continuity and no continuity between specified terminals on A/F heater relay. See Fig. 97 . 2. To test A/F heater relay operation, apply battery voltage and ground to A/F heater relay. Using ohmmeter, check for continuity between specified terminals on A/F heater relay. See Fig. 97 . Replace A/F heater relay if defective. CIRCUIT OPENING RELAY WARNING: On Prius, read service precautions before proceeding with service procedure. See SERVICE PRECAUTIONS . 1. Ensure ignition is off. Remove circuit opening relay. See CIRCUIT OPENING RELAY LOCATION table. See Fig. 99 -Fig. 108 . CIRCUIT OPENING RELAY LOCATION (1) Application Location Camry & Camry In Fuse/Relay Box At Driver's Side Solara Front Corner Of Engine Compartment Celica In Fuse/Relay Box At driver's side Front Corner Of Engine Compartment, Just In Front Of Strut Tower Corolla Center Relay In Relay Box Behind Driver's Side Kick Panel ECHO In Fuse/Relay Box Behind Driver's Side Of Instrument Panel Highlander In Relay Box Just Above Driver's Side Kick Panel MR2 In Relay Box On Firewall At Driver's Side Front Corner Of Engine Compartment Prius & RAV4 In Fuse/Relay Box At Driver's Side Front Corner Of Engine Compartment Tacoma Behind Lower Instrument Panel Cover, Next To Driver's Side Of Steering Column (1) Circuit opening relay may be marked as CIR OPN relay. 2. To test circuit opening relay continuity, using ohmmeter, check for continuity and no continuity between specified terminals on circuit opening relay. See Fig. 109 and Fig. 110 . 3. To test circuit opening relay operation, apply battery voltage and ground to circuit opening relay. Using ohmmeter, check for continuity between specified terminals on circuit opening relay. See Fig. 109 and Fig. 110 . Replace circuit opening relay if defective.

2002 ENGINE PERFORMANCE System & Component Testing - 4-Cylinder

Fig. 102: Locating Circuit Opening Relay (Corolla) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 ENGINE PERFORMANCE System & Component Testing - 4-Cylinder

Fig. 108: Locating Circuit Opening Relay (Tacoma) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. EFI MAIN RELAY NOTE: On Corolla, EFI main relay may also be referred to as EFI relay or F-HTR relay. On all other models, EFI main relay may also be referred to as EFI relay. WARNING: On Prius, read service precautions before proceeding with service procedure. See SERVICE PRECAUTIONS . 1. Ensure ignition is off. Remove EFI main relay. See EFI MAIN RELAY LOCATION table. EFI MAIN RELAY LOCATION Application Location Camry & Camry Solara In Fuse/Relay Box At Driver's Side Front Corner Of Engine Compartment

2002 ENGINE PERFORMANCE System & Component Testing - 4-Cylinder

Celica, Corolla, ECHO & Highlander

In Fuse/Relay Box At Driver's Side Front Corner Of Engine Compartment, Just In Front Of Strut Tower MR2 In Relay Box On Firewall At Driver's Side Front Corner Of Engine Compartment Prius, RAV4 & Tacoma In Fuse/Relay Box At Driver's Side Front Corner Of Engine Compartment 2. To test EFI main relay continuity, using ohmmeter, check for continuity and no continuity between specified terminals on EFI main relay. See Fig. 109 and Fig. 110 . 3. To test EFI main relay operation, apply battery voltage and ground to EFI main relay. Using ohmmeter, check for continuity between specified terminals on EFI main relay. See Fig. 109 and Fig. 110 . Replace EFI main relay if defective.

2002 ENGINE PERFORMANCE System & Component Testing - 4-Cylinder

Fig. 109: Testing Circuit Opening Relay Or EFI Main Relay (Camry, Celica, Corolla, ECHO, Highlander & Prius) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 ENGINE PERFORMANCE System & Component Testing - 4-Cylinder

HTR SUB1 RELAY NOTE:

ECHO

HTR SUB1 relay may also be referred to as heater sub relay.

1. Remove HTR SUB1 relay from fuse/relay box located at driver's side front corner of engine compartment, just in front of strut tower. See Fig. 111 . 2. Note terminals on HTR SUB1 relay. See Fig. 111 . To test HTR SUB1 relay continuity, using ohmmeter, check that continuity exists between terminals No. 1 and 2 on HTR SUB1 relay and that no continuity exists between terminals No. 3 and 5 on HTR SUB1 relay. If continuity and no continuity are as specified, go to next step. If continuity and no continuity are not as specified, replace HTR SUB1 relay. 3. To test HTR SUB1 relay operation, apply battery voltage and ground to terminals No. 1 and 2 on HTR SUB1 relay. Using ohmmeter, check that continuity exists between terminals No. 3 and 5 on HTR SUB1 relay. Replace HTR SUB1 relay if continuity does not exist between terminals No. 3 and 5.

2002 ENGINE PERFORMANCE System & Component Testing - 4-Cylinder

Fig. 111: Locating HTR SUB1 Relay & Identifying HTR SUB1 Relay Terminals (ECHO) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. IG2 RELAY NOTE:
Celica

IG2 relay may also be referred to as ignition relay.

IG2 relay is located in fuse/relay box at driver's side front corner of engine compartment, just in front of strut tower. Testing information is not available from manufacturer. Consult wiring diagram for IG2 relay testing. See WIRING DIAGRAMS article.
MR2

2002 ENGINE PERFORMANCE System & Component Testing - 4-Cylinder

1. Remove IG2 relay from relay box on firewall at driver's side front corner of engine compartment. See Fig. 105 . 2. To test IG2 relay continuity, using ohmmeter, check for continuity and no continuity between specified terminals on IG2 relay. See Fig. 112 . 3. To test IG2 relay operation, apply battery voltage and ground to IG2 relay. Using ohmmeter, check for continuity between specified terminals on IG2 relay. See Fig. 112 . Replace IG2 relay if defective.
Prius

WARNING: Read service precautions before proceeding with service procedure. See SERVICE PRECAUTIONS . IG2 relay is located in fuse/relay box at driver's side front corner of engine compartment. Testing information is not available from manufacturer. Consult wiring diagram for IG2 relay testing. See WIRING DIAGRAMS article.
RAV4

1. Remove IG2 relay from relay box located at driver's side front corner of engine compartment. See Fig. 107 . 2. To test IG2 relay continuity, using ohmmeter, check for continuity and no continuity between specified terminals on IG2 relay. See Fig. 112 . 3. To test IG2 relay operation, apply battery voltage and ground to IG2 relay. Using ohmmeter, check for continuity between specified terminals on IG2 relay. See Fig. 112 . Replace IG2 relay if defective.

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FUEL SYSTEMS
FUEL SYSTEM PRESSURE RELEASE WARNING: ALWAYS release fuel pressure before disconnecting any fuel injectionrelated component. DO NOT allow fuel to contact engine or electrical components. For fuel system pressure release procedures, see FUEL SYSTEM PRESSURE RELEASE under FUEL SYSTEMS in REMOVAL, OVERHAUL & INSTALLATION - 4-CYLINDER article. FUEL DELIVERY NOTE: For fuel system pressure testing, see FUEL PRESSURE under FUEL SYSTEMS in BASIC DIAGNOSTIC PROCEDURES - 4-CYLINDER article.

Circuit Opening Relay

See CIRCUIT OPENING RELAY under MODULES, MOTORS, RELAYS & SOLENOIDS.
EFI Main Relay

See EFI MAIN RELAY under MODULES, MOTORS, RELAYS & SOLENOIDS.
Fuel Pump Resistance & Operation (Camry)

1. Manufacturer lists checking fuel pump resistance and operation with fuel pump removed from fuel tank and fuel pump mounting bracket. For removal of fuel pump from fuel tank and fuel pump mounting bracket, see FUEL PUMP under FUEL SYSTEMS in REMOVAL, OVERHAUL & INSTALLATION - 4-CYLINDER article. 2. To test fuel pump resistance, using ohmmeter, check resistance between electrical terminals on fuel pump. See Fig. 113 . Replace fuel pump if resistance is not .20-3.00 ohms at 68F (20C). See FUEL PUMP under FUEL SYSTEMS in REMOVAL, OVERHAUL & INSTALLATION - 4-CYLINDER article. CAUTION: When testing fuel pump operation, DO NOT apply battery voltage to fuel pump for more than 10 seconds or fuel pump may be damaged. When testing fuel pump operation, keep fuel pump away from battery as far as possible. Always connect jumper wires to fuel pump and then to the battery when applying battery voltage to fuel pump.

2002 ENGINE PERFORMANCE System & Component Testing - 4-Cylinder

Fig. 113: Testing Fuel Pump Resistance & Operation (Camry) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 3. To test fuel pump operation, apply battery voltage and ground to (+) and (-) terminals on fuel pump. See Fig. 113 . DO NOT apply battery voltage to fuel pump for more than 10 seconds. Replace fuel pump if fuel pump does not operate. See FUEL PUMP under FUEL SYSTEMS in REMOVAL, OVERHAUL & INSTALLATION - 4-CYLINDER article.
Fuel Pump Resistance & Operation (Camry Solara, Celica, Corolla, ECHO, Highlander, MR2, Prius, RAV4 & Tacoma

WARNING: On Prius, read service precautions before proceeding with service procedure. See SERVICE PRECAUTIONS . 1. On Camry Solara, Celica, Corolla, ECHO and Prius, remove rear seat cushion, cover plate on floor panel and remaining necessary covers for access to electrical connector for fuel pump. 2. On Highlander, remove driver's side and passenger's side rear seats and cover plate on floor panel for access to electrical connector for fuel pump. 3. On MR2, remove luggage compartment lids, quarter trim covers, lower trim covers and luggage compartment boxes behind driver's and passenger's seats, and cover plate on floor panel for access to electrical connector for fuel pump. See Fig. 123 . For additional information on removal of luggage

2002 ENGINE PERFORMANCE System & Component Testing - 4-Cylinder

4. 5. 6. 7.

compartment components, see FUEL PUMP under FUEL SYSTEMS in REMOVAL, OVERHAUL & INSTALLATION - 4-CYLINDER article. On RAV4, remove driver's side rear seat and cover plate on floor panel for access to electrical connector for fuel pump. On Tacoma, it may be necessary to lower fuel tank for access to electrical connector for fuel pump. On all models, disconnect electrical connector for fuel pump. This is electrical connector for fuel pump and fuel gauge sending unit and is located on top of fuel tank, near fuel pump. To test fuel pump resistance, using ohmmeter, check resistance between specified terminals on fuel pump electrical connector or fuel pump. See Fig. 114 -Fig. 122 . Replace fuel pump if resistance is not .20-3.00 ohms at 68F (20C). On Prius, it may be necessary to replace fuel pump and fuel tank as an assembly. Consult parts department for parts availability. See FUEL PUMP under FUEL SYSTEMS in REMOVAL, OVERHAUL & INSTALLATION - 4-CYLINDER article. CAUTION: When applying battery voltage to fuel pump, DO NOT apply battery voltage for more than 10 seconds or fuel pump may be damaged. Keep battery as far away from fuel pump as possible. Always connect jumper wires to fuel pump first, and then to battery, when applying battery voltage to fuel pump.

8. To test fuel pump operation, apply battery voltage and ground to (+) and (-) terminals on electrical connector or fuel pump. See Fig. 114 -Fig. 122 . DO NOT apply battery voltage to fuel pump for more than 10 seconds. Replace fuel pump and/or lead wire (if equipped) if fuel pump fails to operate. On Prius, it may be necessary to replace fuel pump and fuel tank as an assembly. Consult parts department for parts availability. See FUEL PUMP under FUEL SYSTEMS in REMOVAL, OVERHAUL & INSTALLATION - 4-CYLINDER article.

2002 ENGINE PERFORMANCE System & Component Testing - 4-Cylinder

Fig. 116: Testing Fuel Pump Resistance & Operation (Corolla) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 ENGINE PERFORMANCE System & Component Testing - 4-Cylinder

Fig. 123: Locating Luggage Compartment Components (MR2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. FUEL CONTROL
Fuel Injectors (Camry)

1. To check for fuel injector operation, using stethoscope, listen for clicking sound at each fuel injector, or feel for fuel injector operation at fuel injector with engine cranking or with engine running. If fuel injector operation does not exist, check for loose connection at electrical connector for fuel injector. If

2002 ENGINE PERFORMANCE System & Component Testing - 4-Cylinder

2.

3.

4. 5. 6. 7. 8. 9.

10. 11.

electrical connector for fuel injector is okay, go to next step. Ensure ignition is off. Disconnect electrical connector at fuel injector. Using ohmmeter, check resistance between electrical terminals on fuel injector. Replace fuel injector if resistance is not within specification. See FUEL INJECTOR RESISTANCE table. See FUEL RAILS & FUEL INJECTORS under FUEL SYSTEMS in REMOVAL, OVERHAUL & INSTALLATION - 4CYLINDER article. If fuel injector operates and fuel injector resistance is within specification, go to next step. If fuel injector resistance is within specification but fuel injector does not operate, check wiring circuit to fuel injector. See WIRING DIAGRAMS article. If problem exists in fuel injector or wiring circuit and misfire exists, a Diagnostic Trouble Code (DTC) may be stored in Engine Control Module (ECM). See TESTING PROCEDURE under SELF-DIAGNOSTIC SYSTEM in appropriate SELFDIAGNOSTICS article for retrieving of DTCs. To check fuel injector volume, remove fuel injector. See FUEL RAILS & FUEL INJECTORS under FUEL SYSTEMS in REMOVAL, OVERHAUL & INSTALLATION - 4-CYLINDER article. Remove fuel pipe clamp from end of fuel pipe at fuel pipe fitting if not previously done. See Fig. 124 . Ensure area around fuel pipe and disconnect fitting is clean. Depress both tabs and pull fuel pipe with disconnect fitting from fuel pipe fitting. See Fig. 124 . Use care when disconnecting fuel pipe, as some residual fuel pressure may still exist in fuel system. Purchase fuel pipe (part No. 23901-28130) from parts department. Remove fuel pipe connector from end of NEW fuel pipe. See Fig. 125 . Install fuel pipe connector on fuel pipe fitting. See Fig. 126 . Ensure fuel pipe connector is securely attached on fuel pipe fitting is fully seated. Connect delivery hose from Fuel Injector Measuring Set (SST 09268-41047) to fuel pipe connector. Check that "O" ring is installed on top of fuel injector. Using clamp and union from fuel injector measuring set, connect fuel injector to delivery hose. See Fig. 126 . Place vinyl tube on end of fuel injector to prevent fuel spillage. Place fuel injector into a clean graduated container. Connect Toyota hand-held tester to data link connector No. 3 at driver's side of instrument panel. See Fig. 8 . Turn ignition on and then turn hand-held tester on. Select ACTIVE TEST MODE on handheld tester. Using hand-held tester manufacturer's instructions, activate fuel pump. NOTE: If hand-held tester is not available, fuel pump may also be operated to pressurize fuel system by removing circuit opening relay from fuse/relay box and installing jumper wire between FP and +B terminals in fuse/relay box for circuit opening relay and then turning ignition on. See Fig. 127 . Fuse/relay box is located at driver's side front corner of engine compartment.

12. Connect Fuel Injector Tester (09842-30080) to fuel injector for 15 seconds. See Fig. 128 . Measure fuel injector volume. Test each fuel injector 2-3 times. Replace fuel injector if fuel injector volume is not within specification. See FUEL INJECTOR VOLUME SPECIFICATIONS table. Ensure difference between fuel injector volume on all fuel injectors is within specification. See FUEL INJECTOR VOLUME SPECIFICATIONS table. 13. Disconnect fuel injector tester. Ensure fuel leakage from end of fuel injector does not exceed one drop in 12 minutes. Replace fuel injector if leakage exceeds one drop in 12 minutes. Disconnect negative battery cable. Remove test equipment. 14. Install fuel pipe on fuel pipe fitting. Pull on fuel pipe to ensure fuel pipe is properly locked on fuel pipe fitting. Reinstall fuel pipe clamp. Install negative battery cable. Check for fuel leaks by operating

2002 ENGINE PERFORMANCE System & Component Testing - 4-Cylinder

the fuel pump by using hand-held tester or connecting battery voltage to fuel pump. NOTE: It may be possible that power sun roof may not operate properly after battery was disconnected. If power sun roof does not operate properly, perform power sun roof reinitialization procedure. See appropriate POWER SUN ROOF REINITIALIZATION PROCEDURE under PROGRAMMING.

2002 ENGINE PERFORMANCE System & Component Testing - 4-Cylinder

Fig. 126: Connections For Testing Typical Fuel Injector (Camry, Celica, Corolla, ECHO, Highlander, MR2, Prius & RAV4) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 ENGINE PERFORMANCE System & Component Testing - 4-Cylinder

Fig. 128: Connecting Fuel Injector Tester Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Fuel Injectors (Camry Solara)

1. To check for fuel injector operation, using stethoscope, listen for clicking sound at each fuel injector, or feel for fuel injector operation at fuel injector with engine cranking or with engine running. If fuel injector operation does not exist, check for loose connection at electrical connector for fuel injector. If electrical connector for fuel injector is okay, go to next step. 2. Ensure ignition is off. Disconnect electrical connector at fuel injector. Using ohmmeter, check resistance between electrical terminals on fuel injector. Replace fuel injector if resistance is not within specification. See FUEL INJECTOR RESISTANCE table. See FUEL RAILS & FUEL INJECTORS under FUEL SYSTEMS in REMOVAL, OVERHAUL & INSTALLATION - 4CYLINDER article. 3. If fuel injector operates and fuel injector resistance is within specification, go to next step. If fuel injector resistance is within specification but fuel injector does not operate, check wiring circuit to fuel injector. See WIRING DIAGRAMS article. If problem exists in fuel injector or wiring circuit and misfire exists, a Diagnostic Trouble Code (DTC) may be stored in Engine Control Module (ECM). See TESTING PROCEDURE under SELF-DIAGNOSTIC SYSTEM in appropriate SELFDIAGNOSTICS article for retrieving of DTCs. 4. To check fuel injector volume, remove fuel injector. See FUEL RAILS & FUEL INJECTORS under FUEL SYSTEMS in REMOVAL, OVERHAUL & INSTALLATION - 4-CYLINDER article. 5. Remove fuel pipe clamp from fuel pipe at fuel filter if not previously done. Perform STEP 1 in illustration. See Fig. 129 . Ensure area around fuel pipe and fuel filter is clean. 6. Depress both sides of retainer and pull fuel pipe with disconnect fitting from fuel filter. Perform STEP 2 in illustration. See Fig. 129 . Use care when disconnecting fuel pipe from fuel filter, as some

2002 ENGINE PERFORMANCE System & Component Testing - 4-Cylinder

7. 8. 9.

10. 11.

residual fuel pressure may still exist in the fuel system. Purchase fuel pipe (part No. 23901-22070) from parts department. Remove fuel pipe connector from end of NEW fuel pipe. See Fig. 130 . Install fuel pipe connector on fuel pipe fitting at fuel filter. See Fig. 131 . Ensure fuel pipe connector is securely attached on fuel pipe fitting. Connect delivery hose from Fuel Injector Measuring Set (SST 09268-41047) to fuel pipe connector. Check that grommet and "O" ring are installed on top of fuel injector. Using clamp and union from fuel injector measuring set, connect fuel injector to delivery hose. See Fig. 131 . Place vinyl tube on end of fuel injector to prevent fuel spillage. Place fuel injector into a clean graduated container. Connect Toyota hand-held tester to data link connector No. 3 at driver's side of instrument panel. See Fig. 9 . Turn ignition on and then turn hand-held tester on. Select ACTIVE TEST MODE on handheld tester. Using hand-held tester manufacturer's instructions, activate fuel pump. NOTE: If hand-held tester is not available, fuel pump may also be operated to pressurize fuel system by applying battery voltage to electrical terminals on fuel pump. For operating of fuel pump, see appropriate FUEL PUMP RESISTANCE & OPERATION procedure under FUEL DELIVERY under FUEL SYSTEMS.

12. Connect Fuel Injector Tester (09842-30070) to fuel injector for 15 seconds. See Fig. 128 . Measure fuel injector volume. Test each fuel injector 2-3 times. Replace fuel injector if fuel injector volume is not within specification. See FUEL INJECTOR VOLUME SPECIFICATIONS table. Ensure difference between fuel injector volume on all fuel injectors is within specification. See FUEL INJECTOR VOLUME SPECIFICATIONS table. 13. Disconnect fuel injector tester. Ensure fuel leakage from end of fuel injector does not exceed one drop in 12 minutes. Replace fuel injector if leakage exceeds one drop in 12 minutes. Disconnect negative battery cable. Remove test equipment. CAUTION: DO NOT reuse old retainer when installing fuel pipe on fuel filter. Always use a NEW retainer. 14. Apply light coat of engine oil on tip of fuel pipe fitting on fuel filter to allow for ease of disconnect fitting and fuel pipe installation. Using NEW retainer, install fuel pipe on fuel filter until "click" sound is heard. DO NOT reuse old retainer. Pull on fuel pipe to ensure fuel pipe is properly locked on fuel filter. 15. Reinstall fuel pipe clamp. Install negative battery cable. Check for fuel leaks by activating the fuel pump by using hand-held tester or connecting battery voltage to fuel pump.

2002 ENGINE PERFORMANCE System & Component Testing - 4-Cylinder

Fig. 130: Identifying Fuel Pipe Connector (Camry Solara, Celica, Corolla & MR2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 ENGINE PERFORMANCE System & Component Testing - 4-Cylinder

Fig. 131: Connections For Testing Fuel Injector (Camry Solara) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Fuel Injectors (Celica, Corolla, ECHO, Highlander, MR2, Prius & RAV4)

WARNING: On Prius, read service precautions before proceeding with service procedure. See SERVICE PRECAUTIONS . 1. To check for fuel injector operation, remove No. 2 cylinder head cover on top of engine (if equipped) any other components for access to fuel injectors. Using stethoscope, listen for clicking sound at each fuel injector, or feel for fuel injector operation at fuel injector with engine cranking or with engine running. If fuel injector operation does not exist, check for loose connection at electrical connector for fuel injector. If electrical connector for fuel injector is okay, go to next step. 2. Ensure ignition is off. Disconnect electrical connector at fuel injector. Using ohmmeter, check resistance between electrical terminals on fuel injector. Replace fuel injector if resistance is not within specification. See FUEL INJECTOR RESISTANCE table. See FUEL RAILS & FUEL INJECTORS under FUEL SYSTEMS in REMOVAL, OVERHAUL & INSTALLATION - 4CYLINDER article. 3. If fuel injector operates and fuel injector resistance is within specification, go to next step. If fuel injector resistance is within specification but fuel injector does not operate, check wiring circuit to fuel injector. See WIRING DIAGRAMS article. If problem exists in fuel injector or wiring circuit and misfire exists, a Diagnostic Trouble Code (DTC) may be stored in Engine Control Module (ECM). See TESTING PROCEDURE under SELF-DIAGNOSTIC SYSTEM in appropriate SELF-

2002 ENGINE PERFORMANCE System & Component Testing - 4-Cylinder

4. 5.

6.

7.

8.

DIAGNOSTICS article for retrieving of DTCs. To check fuel injector volume, remove fuel injector. See FUEL RAILS & FUEL INJECTORS under FUEL SYSTEMS in REMOVAL, OVERHAUL & INSTALLATION - 4-CYLINDER article. On Celica, Corolla, ECHO and MR2, remove fuel pipe clamp from end of fuel pipe at end of fuel rail if not previously done. Perform STEP 1 in illustration. See Fig. 132 -Fig. 134 and Fig. 136 . Ensure area around fuel pipe and disconnect fitting is clean. Depress both sides of retainer and pull fuel pipe with disconnect fitting from fuel pipe fitting. Perform STEP 2 in illustration. See Fig. 132 -Fig. 134 and Fig. 136 . Use care when disconnecting fuel pipe, as some residual fuel pressure may still exist in fuel system. Go to step 8 . On Highlander and RAV4, remove fuel pipe clamp from end of fuel pipe at end of fuel rail if not previously done. See Fig. 135 and Fig. 138 . Depress both tabs and pull fuel pipe with disconnect fitting from fuel pipe fitting. See Fig. 135 and Fig. 138 . Use care when disconnecting fuel pipe, as some residual fuel pressure may still exist in fuel system. Go to step 8 . On Prius, depress both sides of retainer and pull fuel pipe with disconnect fitting from fuel pipe fitting. See Fig. 137 . Use care when disconnecting fuel pipe, as some residual fuel pressure may still exist in fuel system. Go to next step. On all models, purchase appropriate fuel pipe from parts department. See FUEL PIPE IDENTIFICATION table. Remove fuel pipe connector from end of NEW fuel pipe. See Fig. 125 and Fig. 130 . FUEL PIPE IDENTIFICATION Application Fuel Pipe Part No. Celica 1.8L 23901-22100 1ZZ-FE 1.8L 23271-88600 2ZZ-GE Corolla 23901-22010 ECHO 23901-21020 Or 23901-22010 Highlander 23901-28070 MR2 23901-22070 Prius 23901-21020 RAV4 23901-22110

9. Install fuel pipe connector on fuel pipe fitting and retainer (if equipped). See Fig. 126 . Ensure fuel pipe connector is securely attached on fuel pipe fitting and retainer (if equipped) is fully seated. 10. Connect delivery hose from Fuel Injector Measuring Set (SST 09268-41047) to fuel pipe connector. Check that grommet (if equipped) and "O" ring are installed on top of fuel injector. Using clamp and union from fuel injector measuring set, connect fuel injector to delivery hose. See Fig. 126 . 11. Place vinyl tube on end of fuel injector to prevent fuel spillage. Place fuel injector into a clean graduated container. 12. Connect Toyota hand-held tester to data link connector No. 3 at driver's side of instrument panel. See Fig. 10 -Fig. 16 . Turn ignition on and then turn hand-held tester on. Select ACTIVE TEST MODE on hand-held tester. Using hand-held tester manufacturer's instructions, activate fuel pump. NOTE: If hand-held tester is not available, fuel pump may also be operated to pressurize fuel system by applying battery voltage to electrical

2002 ENGINE PERFORMANCE System & Component Testing - 4-Cylinder

terminals on fuel pump. For operating of fuel pump, see appropriate FUEL PUMP RESISTANCE & OPERATION procedure under FUEL DELIVERY under FUEL SYSTEMS. 13. Connect Fuel Injector Tester (09842-30080) to fuel injector for 15 seconds. See Fig. 128 . Measure fuel injector volume. Test each fuel injector 2-3 times. Replace fuel injector if fuel injector volume is not within specification. See FUEL INJECTOR VOLUME SPECIFICATIONS table. Ensure difference between fuel injector volume on all fuel injectors is within specification. See FUEL INJECTOR VOLUME SPECIFICATIONS table. 14. Disconnect fuel injector tester. Ensure fuel leakage from end of fuel injector does not exceed one drop in 12 minutes. Replace fuel injector if leakage exceeds one drop in 12 minutes. Disconnect negative battery cable. Remove test equipment. 15. On Celica, Corolla, ECHO, MR2 and Prius, DO NOT reuse old retainer when installing fuel pipe on fuel pipe fitting. Always use a NEW retainer. Apply light coat of engine oil on tip of fuel pipe fitting to allow for ease of disconnect fitting and fuel pipe installation. Using NEW retainer, install fuel pipe on fuel pipe fitting until "click" sound is heard. DO NOT reuse old retainer. Pull on fuel pipe to ensure fuel pipe is properly locked on fuel pipe fitting. Reinstall fuel pipe clamp (if equipped). Go to step 17 . 16. On Highlander and RAV4, install fuel pipe on fuel pipe fitting. Pull on fuel pipe to ensure fuel pipe is properly locked on fuel pipe fitting. Reinstall fuel pipe clamp. Go to next step. 17. On all models, install negative battery cable. Check for fuel leaks by operating the fuel pump by using hand-held tester or connecting battery voltage to fuel pump. NOTE: On Celica, it may be possible that power sun roof may not operate properly after battery was disconnected. If power sun roof does not operate properly, perform power sun roof reinitialization procedure. See appropriate POWER SUN ROOF REINITIALIZATION PROCEDURE under PROGRAMMING.

Fuel Injectors (Tacoma)

1. To check for fuel injector operation, using stethoscope, listen for clicking sound at each fuel injector, or feel for fuel injector operation at fuel injector with engine cranking or with engine running. If fuel injector operation does not exist, check for loose connection at electrical connector for fuel injector. If electrical connector for fuel injector is okay, go to next step. 2. Ensure ignition is off. Disconnect electrical connector at fuel injector. Using ohmmeter, check resistance between electrical terminals on fuel injector. Replace fuel injector if resistance is not within specification. See FUEL INJECTOR RESISTANCE table. See FUEL RAILS & FUEL INJECTORS under FUEL SYSTEMS in REMOVAL, OVERHAUL & INSTALLATION - 4CYLINDER article. 3. If fuel injector operates and fuel injector resistance is within specification, go to next step. If fuel injector resistance is within specification but fuel injector does not operate, check wiring circuit to fuel injector. See WIRING DIAGRAMS article. If problem exists in fuel injector or wiring circuit and misfire exists, a Diagnostic Trouble Code (DTC) may be stored in Engine Control Module (ECM). See TESTING PROCEDURE under SELF-DIAGNOSTIC SYSTEM in appropriate SELFDIAGNOSTICS article for retrieving of DTCs. 4. To check fuel injector volume, remove fuel injector. See FUEL RAILS & FUEL INJECTORS under FUEL SYSTEMS in REMOVAL, OVERHAUL & INSTALLATION - 4-CYLINDER article. Ensure area around fuel hoses on fuel filter is clean. Remove union bolts with gaskets, and disconnect fuel hose from fuel filter. See Fig. 139 .

2002 ENGINE PERFORMANCE System & Component Testing - 4-Cylinder

5. Install union, delivery hose, gaskets and union bolt from Fuel Injector Measuring Set (SST 0926841047) on fuel filter. See Fig. 139 . Tighten union bolt to 21 ft. lbs. (29 N.m). 6. Check that "O" ring is installed on top of fuel injector. Using clamp and union from fuel injector measuring set, connect fuel injector to delivery hose. See Fig. 139 . 7. Remove fuel pressure regulator from fuel rail. See FUEL PRESSURE REGULATOR under FUEL SYSTEMS in REMOVAL, OVERHAUL & INSTALLATION - 4-CYLINDER article. Using NEW "O" ring, install union on fuel pressure regulator. See Fig. 139 . Connect delivery hose to union and fuel return hose on fuel pressure regulator. 8. Place vinyl tube on end of fuel injector to prevent fuel spillage. Place fuel injector into a clean graduated container. 9. Connect Toyota hand-held tester to data link connector No. 3 at driver's side of instrument panel. See Fig. 17 . Turn ignition on and then turn hand-held tester on. Select ACTIVE TEST MODE on handheld tester. Using hand-held tester manufacturer's instructions, activate fuel pump. NOTE: If hand-held tester is not available, fuel pump may also be operated to pressurize fuel system by applying battery voltage to electrical terminals on fuel pump. For operating of fuel pump, see appropriate FUEL PUMP RESISTANCE & OPERATION procedure under FUEL DELIVERY under FUEL SYSTEMS.

10. Connect Fuel Injector Tester (09842-30070) to fuel injector for 15 seconds. See Fig. 128 . Measure fuel injector volume. Test each fuel injector 2-3 times. Replace fuel injector if fuel injector volume is not within specification. See FUEL INJECTOR VOLUME SPECIFICATIONS table. Ensure difference between fuel injector volume on all fuel injectors is within specification. See FUEL INJECTOR VOLUME SPECIFICATIONS table. 11. Disconnect fuel injector tester. Ensure fuel leakage from end of fuel injector does not exceed one drop in 12 minutes. Replace fuel injector if leakage exceeds one drop in 12 minutes. Disconnect negative battery cable. Remove test equipment. 12. Using NEW gaskets, install fuel hose on top of fuel filter. Tighten union bolt to 21 ft. lbs. (29 N.m). Reinstall fuel pressure regulator. Install negative battery cable. Check for fuel leaks by operating the fuel pump by using hand-held tester or connecting battery voltage to fuel pump. FUEL INJECTOR RESISTANCE Application Camry, Camry Solara, Celica, Corolla, ECHO, Highlander, MR2, Prius & RAV4 Tacoma FUEL INJECTOR VOLUME SPECIFICATIONS Application Volume Camry Camry Solara Celica Corolla ECHO Highlander

Ohms @ 68F (20C) 13.40-14.20 12.00-16.00

cc (Cu. In.) 68-82 (4.1-5.0) 69-82 (4.2-5.0) 47-58 (2.8-3.5) 60-73 (3.7-4.5) 47-58 (2.8-3.5) 69-82 (4.2-5.0)

2002 ENGINE PERFORMANCE System & Component Testing - 4-Cylinder

MR2 Prius RAV4 Tacoma Maximum Difference Between Each Fuel Injector Camry & Camry Solara Celica Corolla ECHO Highlander & MR2 Prius RAV4 Tacoma

60-73 (3.7-4.5) 36-46 (2.1-2.8) 53-65 (3.2-3.9) 71-86 (4.3-5.2) 14 (.85) 10 (.61) 13 (.80) 10 (.61) 13 (.80) 10 (.61) 6 (.37) 15 (.91)

2002 ENGINE PERFORMANCE System & Component Testing - 4-Cylinder

Fig. 133: Locating Fuel Pipe Clamp & Disconnecting Fuel Pipe From Fuel Pipe Fitting (Corolla) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 ENGINE PERFORMANCE System & Component Testing - 4-Cylinder

Fig. 139: Connections For Testing Fuel Injector (Tacoma) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Fuel Cut System (Camry & Highlander)

1. Connect Toyota hand-held tester or scan tool to data link connector No. 3 at driver's side of instrument panel. See Fig. 8 and Fig. 13 . Hand-held tester or scan tool is used to read engine RPM. Start engine and warm engine to normal operating temperature. 2. Gradually increase engine speed to 3500 RPM. Using stethoscope, check for fuel injector operating sound. Ensure when throttle lever is released, fuel injector stops operating momentarily and then resumes operating. Shut engine off. Remove hand-held tester or scan tool.
Fuel Cut System (Camry Solara, Celica, Corolla, ECHO, MR2, RAV4 & Tacoma)

1. Connect Toyota hand-held tester or scan tool to data link connector No. 3 at driver's side of instrument panel. See Fig. 9 -Fig. 17 . Hand-held tester or scan tool is used to read engine RPM. Start engine and warm engine to normal operating temperature. 2. Ensure A/C is off. Gradually increase engine speed to 3500 RPM. Using stethoscope, check for fuel injector operating sound. Ensure when throttle lever is released, fuel injector stops operating momentarily and then resumes operating (fuel return RPM). 3. Ensure fuel return RPM is within specification. See FUEL CUT SYSTEM SPECIFICATIONS table. Shut engine off. Remove hand-held tester or scan tool. FUEL CUT SYSTEM SPECIFICATIONS (1) Application Camry Solara A/T M/T Celica, Corolla, ECHO, MR2 & RAV4

Fuel Return RPM 1500 1200 1400

2002 ENGINE PERFORMANCE System & Component Testing - 4-Cylinder

Tacoma A/T M/T (1) Check with engine at normal operating temperature and A/C off.
Fuel Cut System (Prius)

1500 1400

WARNING: Read service precautions before proceeding with service procedure. See SERVICE PRECAUTIONS . 1. It is necessary to put transit in inspection mode so engine will run continuously when checking fuel cut system. To put transit in inspection mode, perform the following steps within 60 seconds: Ensure ignition is off and then turn ignition on. Ensure transaxle is in Park and then fully depress accelerator pedal 2 times. Place transaxle in Neutral and then fully depress accelerator pedal 2 times. Place transaxle back in Park and then fully depress accelerator pedal 2 times. 2. Check that master warning light on instrument cluster at center of instrument panel is flashing to indicate inspection mode operation. See Fig. 140 . Master warning light may also be referred to as hybrid system error warning light. Turn ignition switch to START position to start engine. Engine will now start and run continuously. 3. Connect Toyota hand-held tester or scan tool to data link connector No. 3 at driver's side of instrument panel. See Fig. 15 . Hand-held tester or scan tool is used to read engine RPM. Warm engine to normal operating temperature. 4. Ensure A/C is off. Gradually increase engine speed to 2250 RPM. Using stethoscope, check for fuel injector operating sound. Ensure when throttle lever is released, fuel injector stops operating momentarily and then resumes operating. Ensure when throttle lever is released, fuel injector stops operating momentarily and then resumes operating at 1400 RPM which is the fuel return RPM. Shut engine off. Remove hand-held tester or scan tool.

2002 ENGINE PERFORMANCE System & Component Testing - 4-Cylinder

Fig. 140: Locating Master Warning Light (Prius) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

IDLE CONTROL SYSTEMS

IDLE AIR CONTROL VALVE
Celica & ECHO

1. Start engine and warm engine to normal operating temperature. Ensure idle speed is within specification. See IDLE SPEED & MIXTURE in ON-VEHICLE ADJUSTMENTS - 4-CYLINDER article. 2. Turn ignition off. Apply parking brake and place transaxle in Neutral. Ensure A/C is off. Install Jumper Wire (SST 09843-18020 or SST 09843-18040) between terminals No. 4 (CG) and No. 13 (TC) on data link connector No. 3. See Fig. 141 . Data link connector No. 3 is located behind driver's side of instrument panel. See Fig. 10 and Fig. 12 . 3. Start engine and note engine speed. Engine speed should increase to 900-1300 RPM for 5 seconds and then return to idle speed. If engine speed is as specified, turn ignition off and remove jumper wire. If engine speed is not as specified, turn ignition off and remove jumper wire. Go to next step. 4. To test Idle Air Control (IAC) valve operation, remove IAC valve from throttle body. See THROTTLE BODY under FUEL SYSTEMS in REMOVAL, OVERHAUL & INSTALLATION 4-CYLINDER article. Check that valve on inside of IAC valve is half open. See Fig. 142 and Fig. 143 . Reinstall electrical connector on IAC valve. 5. Disconnect electrical connector from Engine Coolant Temperature (ECT) sensor. On Celica, ECT sensor is located on flywheel end of cylinder head and contains Gray electrical connector with Green and Brown wires. On ECHO, ECT sensor is located on flywheel end of cylinder head and contains Gray electrical connector with Red/Blue and Brown wires. 6. On all models, turn ignition on. Check that valve on inside of IAC valve moves. Repeatedly disconnect and reconnect electrical connector for IAC valve several times while checking that valve on inside of IAC valve opens and closes. See Fig. 142 and Fig. 143 .

2002 ENGINE PERFORMANCE System & Component Testing - 4-Cylinder

7. Turn ignition off. Reinstall electrical connector on ECT sensor. If IAC valve operates as specified, wiring circuit, Engine Control Module (ECM) and IAC valve are okay. If IAC valve does not operate, check wiring circuit between ECM and IAC valve. On Celica, ECM is located in engine compartment, below cover, just in front of battery, next to driver's side strut tower. On ECHO, ECM is located behind glove box. On all models, for illustration of ECM location, see THEORY & OPERATION article. See WIRING DIAGRAMS article. On all models, if wiring circuit and ECM are okay, replace IAC valve.

Fig. 141: Identifying Terminals On Data Link Connector No. 3 (Celica, ECHO, MR2, RAV4 & Tacoma) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 ENGINE PERFORMANCE System & Component Testing - 4-Cylinder

Fig. 142: Testing Idle Air Control Valve Operation (Celica) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 ENGINE PERFORMANCE System & Component Testing - 4-Cylinder

Fig. 143: Testing Idle Air Control Valve Operation (ECHO & MR2 With Standard Type Manual Transaxle) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Corolla

1. Start engine and warm engine to normal operating temperature. Ensure idle speed is within specification. See IDLE SPEED & MIXTURE in ON-VEHICLE ADJUSTMENTS - 4-CYLINDER article. 2. Turn ignition off. Apply parking brake and place transaxle in Neutral. Ensure A/C is off. Install Jumper Wire (SST 09843-18020 or SST 09843-18040) between terminals TE1 and E1 on data link connector No. 1. See Fig. 144 . Data link connector No. 1 is located at driver's side of engine compartment, near strut tower. 3. Start engine and note engine speed. Engine speed should increase to 900-1300 RPM for 5 seconds and then return to idle speed. If engine speed is as specified, turn ignition off and remove jumper wire. If engine speed is not as specified, turn ignition off and remove jumper wire. Go to next step. 4. To test Idle Air Control (IAC) valve operation, remove IAC valve from throttle body. See THROTTLE BODY under FUEL SYSTEMS in REMOVAL, OVERHAUL & INSTALLATION 4-CYLINDER article. Check that valve on inside of IAC valve is half open. See Fig. 145 . Reinstall electrical connector on IAC valve. 5. Disconnect electrical connector from Engine Coolant Temperature (ECT) sensor. ECT sensor is located on flywheel end of cylinder head and contains Dark Gray electrical connector with White and Brown wires. 6. Turn ignition on. Check that valve on inside of IAC valve moves. Repeatedly disconnect and

2002 ENGINE PERFORMANCE System & Component Testing - 4-Cylinder

reconnect electrical connector for IAC valve several times while checking that valve on inside of IAC valve opens and closes. See Fig. 145 . 7. Turn ignition off. Reinstall electrical connector on ECT sensor. If IAC valve operates as specified, wiring circuit, Engine Control Module (ECM) and IAC valve are okay. If IAC valve does not operate, check wiring circuit between ECM and IAC valve. ECM is located behind stereo on instrument panel, just in front of center console. For illustration of ECM location, see THEORY & OPERATION article. It may be necessary to remove bolts from ECM so electrical connectors can be accessed on ECM. See ENGINE CONTROL MODULE under COMPUTERIZED ENGINE CONTROLS in REMOVAL, OVERHAUL & INSTALLATION - 4-CYLINDER article. See WIRING DIAGRAMS article. If wiring circuit and ECM are okay, replace IAC valve.

Fig. 144: Installing Jumper Wire Between Data Link Connector No. 1 Terminals (Corolla) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 ENGINE PERFORMANCE System & Component Testing - 4-Cylinder

Fig. 145: Testing Idle Air Control Valve Operation (Corolla) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Highlander

1. If problem exists in Idle Air Control (IAC) valve or wiring circuit, a Diagnostic Trouble Code (DTC) P0505 may be stored in Engine Control Module (ECM). See TESTING PROCEDURE under SELFDIAGNOSTIC SYSTEM in appropriate SELF-DIAGNOSTICS article for retrieving of DTCs. 2. To test IAC valve operation, remove IAC valve from throttle body. See THROTTLE BODY under FUEL SYSTEMS in REMOVAL, OVERHAUL & INSTALLATION - 4-CYLINDER article. Reinstall electrical connector on IAC valve. 3. Turn ignition on. Check that valve on inside of IAC valve moves from half open to fully closed, fully open and then returns to half open within .5 seconds. See Fig. 146 . Turn ignition off. If IAC valve operates as specified, wiring circuit, Engine Control Module (ECM) and IAC valve are okay. 4. If IAC valve operates as specified, wiring circuit, Engine Control Module (ECM) and IAC valve are okay. Clear any stored DTCs from ECM after checking IAC valve operation. See CLEARING DIAGNOSTIC TROUBLE CODES under SELF-DIAGNOSTIC SYSTEM in appropriate SELFDIAGNOSTICS article. If IAC valve does not operate, check wiring circuit between ECM and IAC valve. ECM is located behind glove box. For illustration of ECM location, see THEORY & OPERATION article. See WIRING DIAGRAMS article. If wiring circuit and ECM are okay, replace IAC valve.

2002 ENGINE PERFORMANCE System & Component Testing - 4-Cylinder

Fig. 146: Testing Idle Air Control Valve Operation (Highlander & RAV4) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
MR2 With Standard Type Manual Transaxle

NOTE:

Idle Air Control (IAC) valve is used only on models with standard type manual transaxle.

1. Start engine and warm engine to normal operating temperature. Ensure idle speed is within specification. See IDLE SPEED & MIXTURE in ON-VEHICLE ADJUSTMENTS - 4-CYLINDER article. 2. Turn ignition off. Apply parking brake and place transaxle in Neutral. Ensure A/C is off. Install Jumper Wire (SST 09843-18020 or SST 09843-18040) between terminals No. 4 (CG) and No. 13 (TC) on data link connector No. 3. See Fig. 141 . Data link connector No. 3 is located behind driver's side of instrument panel. See Fig. 14 . 3. Start engine and note engine speed. Engine speed should increase to 1000-1500 RPM for 5 seconds and then return to idle speed. If engine speed is as specified, turn ignition off and remove jumper wire. If engine speed is not as specified, turn ignition off and remove jumper wire. Go to next step. 4. To test IAC operation, remove IAC valve from throttle body. See THROTTLE BODY under FUEL SYSTEMS in REMOVAL, OVERHAUL & INSTALLATION - 4-CYLINDER article. Check that valve on inside of IAC valve is half open. See Fig. 143 . Reinstall electrical connector on IAC valve. 5. Turn ignition on. Check that valve on inside of IAC valve moves from half open to fully closed, fully open and then returns to half open within .5 seconds. See Fig. 143 . Turn ignition off. 6. If IAC valve operates as specified, wiring circuit, Engine Control Module (ECM) and IAC valve are okay. If IAC valve does not operate, check wiring circuit between ECM and IAC valve. ECM is located on inside of firewall, directly behind driver's seat and luggage compartment. For illustration of

2002 ENGINE PERFORMANCE System & Component Testing - 4-Cylinder

ECM location, see THEORY & OPERATION article. See ENGINE CONTROL MODULE under COMPUTERIZED ENGINE CONTROLS in REMOVAL, OVERHAUL & INSTALLATION - 4CYLINDER article for removal of components for access to ECM. See WIRING DIAGRAMS article. If wiring circuit and ECM are okay, replace IAC valve.
RAV4

1. Start engine and warm engine to normal operating temperature. Ensure idle speed is within specification. See IDLE SPEED & MIXTURE in ON-VEHICLE ADJUSTMENTS - 4-CYLINDER article. 2. Turn ignition off. Apply parking brake and place transaxle in Neutral. Ensure A/C is off. Install Jumper Wire (SST 09843-18020 or SST 09843-18040) between terminals No. 4 (CG) and No. 13 (TC) on data link connector No. 3. See Fig. 141 . Data link connector No. 3 is located behind driver's side of instrument panel. See Fig. 16 . 3. Start engine and note engine speed. Engine speed should increase to 900-1500 RPM for 5 seconds and then return to idle speed. If engine speed is as specified, turn ignition off and remove jumper wire. If engine speed is not as specified, turn ignition off and remove jumper wire. Go to next step. 4. To test Idle Air Control (IAC) valve operation, remove IAC valve from throttle body. See THROTTLE BODY under FUEL SYSTEMS in REMOVAL, OVERHAUL & INSTALLATION 4-CYLINDER article. Check that valve on inside of IAC valve is half open. See Fig. 146 . Reinstall electrical connector on IAC valve. 5. Turn ignition on. Check that valve on inside of IAC valve moves from half open to fully closed, fully open and then returns to half open within .5 seconds. See Fig. 146 . Turn ignition off. 6. If IAC valve operates as specified, wiring circuit, Engine Control Module (ECM) and IAC valve are okay. If IAC valve does not operate, check wiring circuit between ECM and IAC valve. ECM is located behind passenger's side kick panel, just below instrument panel. For illustration of ECM location, see THEORY & OPERATION article. See WIRING DIAGRAMS article. If wiring circuit and ECM are okay, replace IAC valve.
Tacoma

1. Start engine and warm engine to normal operating temperature. Ensure idle speed is within specification. See IDLE SPEED & MIXTURE in ON-VEHICLE ADJUSTMENTS - 4-CYLINDER article. 2. Turn ignition off. Apply parking brake and place transmission in Neutral. Install Jumper Wire (SST 09843-18020 or SST 09843-18040) between terminals No. 4 (CG) and No. 13 (TC) on data link connector No. 3. See Fig. 141 . Data link connector No. 3 is located behind driver's side of instrument panel. See Fig. 17 . 3. Start engine and note engine speed. Engine speed should increase to 1000-1500 RPM for 5 seconds and then return to idle speed. If engine speed is as specified, turn ignition off and remove jumper wire. If engine speed is not as specified, turn ignition off and remove jumper wire. Go to next step. 4. To test Idle Air Control (IAC) valve operation, remove IAC valve from throttle body. See THROTTLE BODY under FUEL SYSTEMS in REMOVAL, OVERHAUL & INSTALLATION 4-CYLINDER article. Check that valve on inside of IAC valve is half open. See Fig. 147 . Reinstall electrical connector on IAC valve. 5. Disconnect electrical connector from Engine Coolant Temperature (ECT) sensor. ECT sensor is located on coolant housing at rear of cylinder head and contains Dark Gray 2-pin electrical connector with Green/Red and Blue/Black wires. 6. Turn ignition on. Check that valve on inside of IAC valve moves. Repeatedly disconnect and

2002 ENGINE PERFORMANCE System & Component Testing - 4-Cylinder

reconnect electrical connector for IAC valve several times while checking that valve on inside of IAC valve opens and closes. See Fig. 147 . 7. Turn ignition off. Reinstall electrical connector on ECT sensor. If IAC valve operates as specified, wiring circuit, Engine Control Module (ECM) and IAC valve are okay. If IAC valve does not operate, check wiring circuit between ECM and IAC valve. ECM is located behind glove box. For illustration of ECM location, see THEORY & OPERATION article. See WIRING DIAGRAMS article. If wiring circuit and ECM are okay, replace IAC valve.

Fig. 147: Testing Idle Air Control Valve Operation (Tacoma) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. THROTTLE BODY
Camry & Camry Solara

1. Electronic Throttle Control System (ETCS) is used for controlling idle speed. ETCS consists of throttle body, accelerator pedal position sensor, Throttle Position (TP) sensor, throttle control motor and Engine Control Module (ECM). 2. To test throttle control motor operation, turn ignition on. Depress accelerator pedal to operate accelerator pedal position sensor while listing for operating sound at throttle control motor and note that no grinding noise is heard at throttle control motor and throttle body. Accelerator pedal position sensor is located near top of accelerator pedal and throttle control motor is located on the throttle body. See Fig. 148 .

2002 ENGINE PERFORMANCE System & Component Testing - 4-Cylinder

3. If throttle control motor operating sound is heard, go to next step. If throttle control motor operating sound is not heard, throttle control motor, wiring harness or ECM may be defective. ECM is located on behind glove box. For illustration of ECM location, see THEORY & OPERATION article. For wiring of throttle control motor, see WIRING DIAGRAMS article. For testing of throttle control motor, go to step 6 . 4. To test accelerator pedal position sensor, turn ignition off. Connect Toyota hand-held tester or scan tool to data link connector No. 3 at driver's side of instrument panel. See Fig. 8 and Fig. 9 . Turn ignition on. Hand-held tester or scan tool is used to read throttle valve opening which is displayed as a percentage. Ensure Malfunction Indicator Light (MIL) on instrument panel is not illuminated. MIL is displayed as an engine icon. If MIL is not illuminated, go to next step. If MIL is illuminated, a Diagnostic Trouble Code (DTC) may be stored in ECM. See TESTING PROCEDURE under SELFDIAGNOSTIC SYSTEM in appropriate SELF-DIAGNOSTICS article for retrieving of DTCs. 5. Read throttle valve opening on hand-held tester or scan tool by accessing THROTTLE POS under CURRENT DATA. Read throttle valve opening while fully depressing accelerator pedal to operate accelerator pedal position sensor. Throttle valve opening should be 60 percent or more. Turn ignition off. If throttle valve opening is 60 percent or more, go to next step. If throttle valve opening is not at least 60 percent, problem may exist in accelerator position sensor, wiring circuit or ECM. If necessary to check wiring between ECM and accelerator pedal position sensor, see WIRING DIAGRAMS article. ECM is located behind glove box. For illustration of ECM location, see THEORY & OPERATION article. For testing of accelerator pedal position sensor, see ACCELERATOR PEDAL POSITION SENSOR under ENGINE SENSORS & SWITCHES. 6. To test throttle control motor, disconnect electrical connector from side of throttle body. See Fig. 148 . Note electrical terminal identification on throttle body. See Fig. 149 . Using ohmmeter, check resistance between specified terminals on throttle control motor. See THROTTLE CONTROL MOTOR RESISTANCE table. If resistance is within specification, reinstall electrical connector. If resistance is not within specification, replace throttle body with throttle control motor as an assembly. THROTTLE CONTROL MOTOR RESISTANCE Terminal Ohms @ 68F (20C) M+ & M.3-100.0 VC & E2 1.2-3.2 7. To test Throttle Position (TP) sensor, disconnect electrical connector from side of throttle body. See Fig. 148 . Note electrical terminal identification on throttle body. See Fig. 149 . Using ohmmeter, check resistance between VC and E2 terminals on throttle body. Replace throttle body with TP sensor if resistance is not 1200-3200 ohms at 68F (20C).

2002 ENGINE PERFORMANCE System & Component Testing - 4-Cylinder

Fig. 149: Identifying Electrical Terminals On Throttle Body (Camry & Camry Solara) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Celica, Corolla, ECHO, MR2 With Standard Type Manual Transaxle & RAV4

Check that throttle linkage moves freely at throttle body. Procedure for checking vacuum supply at throttle body is not available from manufacturer.
Highlander

1. Check that throttle linkage moves freely at throttle body. Ensure no vacuum ports on throttle body are restricted. Procedure for checking vacuum supply at throttle body is not available from manufacturer. 2. Check that no clearance exists between throttle stop screw and throttle lever when throttle is fully closed. See Fig. 150 . If clearance exists between throttle stop screw and throttle lever with throttle fully closed, go to next step. 3. Loosen lock nut on throttle stop screw. See Fig. 150 . With clearance between throttle stop screw and throttle lever, hold throttle fully closed and tighten throttle stop screw until it just contacts throttle lever. Once throttle stop screw contacts the throttle lever, tighten throttle stop screw an additional 1/4 turn and then tighten lock nut. Ensure Throttle Position (TP) sensor operates properly after performing this procedure. See THROTTLE POSITION SENSOR under ENGINE SENSORS & SWITCHES.

2002 ENGINE PERFORMANCE System & Component Testing - 4-Cylinder

Fig. 150: Locating Throttle Stop Screw & Throttle Lever (Highlander) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
MR2 With Sequential Manual Transaxle

NOTE:

A standard type manual transaxle and a sequential manual transaxle may be used. On models with a standard type manual transaxle, the driver operates the clutch and shifts the transaxle. On models with sequential manual transaxle, the transaxle is electronically controlled and the clutch is operated and transaxle is shifted hydraulically by moving shift lever forward or backward. Sequential manual transaxle may be identified by shift lever pattern which consists of "R", "N", "S" and "+" in place of the conventional type shift lever pattern and there is no clutch pedal. On this model, Electronic Throttle Control System (ETCS) is used for controlling idle speed. ETCS consists of throttle body, accelerator pedal position sensor, Throttle Position (TP) sensor, throttle control motor, magnetic clutch and Engine Control Module (ECM).

1. Ensure throttle cable and throttle lever on throttle body move smoothly. Note location of throttle control motor on throttle body. See Fig. 151 .

2002 ENGINE PERFORMANCE System & Component Testing - 4-Cylinder

Fig. 151: Locating Electronic Throttle Control System Components On Throttle Body (MR2 With Sequential Manual Transaxle) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 2. To check throttle control motor operation, turn ignition on. Rotate throttle lever on throttle body to full throttle while listing for operating sound at throttle control motor and note that no grinding noise is heard at throttle control motor and throttle body. Throttle lever will also rotate accelerator pedal position sensor. 3. If throttle control motor operating sound is heard, go to next step. If throttle control motor operating sound is not heard, throttle control motor, wiring harness or ECM may be defective. ECM is located on inside of firewall, directly behind driver's seat and luggage compartment. For illustration of ECM location, see THEORY & OPERATION article. To remove components for access to ECM, see ENGINE CONTROL MODULE under COMPUTERIZED ENGINE CONTROLS in REMOVAL, OVERHAUL & INSTALLATION - 4-CYLINDER article. Go to step 12 for testing of throttle control motor. For wiring of throttle control motor, see WIRING DIAGRAMS article. 4. To test operation of accelerator pedal position sensor, Toyota hand-held tester may be used or voltmeter may be used. If using hand-held tester, go to next step. If using voltmeter, go to step 8 . 5. Connect hand-held tester to data link connector No. 3 at driver's side of instrument panel. See Fig. 14 . Hand-held tester is used to read throttle valve opening which is displayed as a percentage. Ensure Malfunction Indicator Light (MIL) on instrument panel is not illuminated. MIL is displayed as an engine icon. If MIL is not illuminated, go to next step. If MIL is illuminated, a Diagnostic Trouble Code (DTC) may be stored in ECM. See TESTING PROCEDURE under SELF-DIAGNOSTIC SYSTEM in appropriate SELF-DIAGNOSTICS article for retrieving of DTCs. 6. Rotate throttle lever on throttle body to full throttle while reading throttle valve opening on hand-held tester which is accessed by THROTTLE POS under CURRENT DATA. Throttle lever will also rotate accelerator pedal position sensor. Throttle valve opening should be 60 percent or more.

2002 ENGINE PERFORMANCE System & Component Testing - 4-Cylinder

7. If throttle valve opening is at least 60 percent, go to step 10 . If throttle valve opening is not at least 60 percent, problem may exist in accelerator pedal position sensor, wiring circuit or ECM. Go to step 16 for testing of accelerator pedal position sensor. For wiring of accelerator pedal position sensor, see WIRING DIAGRAMS article. 8. Access ECM. ECM is located on inside of firewall, directly behind driver's seat and luggage compartment. For illustration of ECM location, see THEORY & OPERATION article. To remove components for access to ECM, see ENGINE CONTROL MODULE under COMPUTERIZED ENGINE CONTROLS in REMOVAL, OVERHAUL & INSTALLATION - 4-CYLINDER article. 9. Ensure ignition is on. Using voltmeter, check voltage between ECM terminals VPA (Blue wire) and E2 (Brown wire) with accelerator pedal released and with accelerator pedal fully depressed. See Fig. 152 . Voltage should .3-.9 volt with accelerator pedal released and 3.2-4.7 volts with accelerator pedal fully depressed. If voltage is within specification, go to next step. If voltage is not within specification, problem may exist in accelerator pedal position sensor, wiring circuit or ECM. Go to step 16 for testing of accelerator pedal position sensor. For wiring of accelerator pedal position sensor, see WIRING DIAGRAMS article.

Fig. 152: Testing Voltage At Engine Control Module Terminals VPA & E2 (MR2 With Sequential Manual Transaxle) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 10. Start engine and allow engine to idle. Check operation of Malfunction Indicator Light (MIL) on instrument panel. MIL is displayed as an engine icon. If MIL is not illuminated, go to next step. If MIL is illuminated, a Diagnostic Trouble Code (DTC) may be stored in Engine Control Module

2002 ENGINE PERFORMANCE System & Component Testing - 4-Cylinder

(ECM). See TESTING PROCEDURE under SELF-DIAGNOSTIC SYSTEM in appropriate SELFDIAGNOSTICS article for retrieving of DTCs. 11. To test operation of air assist system, allow engine to warm to normal operating temperature. Apply parking brake. Place transaxle in Neutral. Ensure A/C is off. Note engine idle speed. Engine idle speed should be 700-800 RPM. If all previous steps have been performed, drive vehicle to verify proper operation of throttle body. 12. To test throttle control motor, disconnect electrical connector at throttle control motor. See Fig. 151 . It may be necessary to remove throttle body for access to electrical connector at throttle control motor. If necessary to remove throttle body, see THROTTLE BODY under FUEL SYSTEMS in REMOVAL, OVERHAUL & INSTALLATION - 4-CYLINDER article. 13. Note terminal identification on throttle control motor. See Fig. 153 . Using ohmmeter, check resistance between specified terminals on throttle control motor. See THROTTLE CONTROL MOTOR RESISTANCE table. If resistance is within specification, reinstall electrical connector. Go to next step. If resistance is not within specification, replace throttle body with throttle control motor as an assembly. THROTTLE CONTROL MOTOR RESISTANCE Terminal No. Ohms @ 68F (20C) 1&2 .3-100.0 3&4 4.2-5.2

Fig. 153: Identifying Terminals & Testing Throttle Control Motor (MR2 With Sequential Manual Transaxle) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 ENGINE PERFORMANCE System & Component Testing - 4-Cylinder

14. To test TP sensor, it may be necessary to remove throttle body for access to electrical connector at TP sensor. If necessary to remove throttle body, see THROTTLE BODY under FUEL SYSTEMS in REMOVAL, OVERHAUL & INSTALLATION - 4-CYLINDER article. 15. Disconnect electrical connector at TP sensor. See Fig. 151 . Using ohmmeter, check resistance between terminals E2 and VC on TP sensor. See Fig. 154 . Replace TP sensor if resistance is not 1200-3200 ohms at 68F (20C). See THROTTLE BODY under FUEL SYSTEMS in REMOVAL, OVERHAUL & INSTALLATION - 4-CYLINDER article. 16. To test accelerator pedal position sensor, it may be necessary to remove throttle body for access to electrical connector at TP sensor. If necessary to remove throttle body, see THROTTLE BODY under FUEL SYSTEMS in REMOVAL, OVERHAUL & INSTALLATION - 4-CYLINDER article. 17. Disconnect electrical connector at accelerator pedal position sensor. See Fig. 151 . Using ohmmeter, check resistance between terminals E2 and VC on accelerator pedal position sensor. See Fig. 155 . Replace accelerator pedal position sensor if resistance is not 1200-3200 ohms at 68F (20C). See THROTTLE BODY under FUEL SYSTEMS in REMOVAL, OVERHAUL & INSTALLATION 4-CYLINDER article.

Fig. 154: Identifying Terminals & Testing Throttle Position Sensor (MR2 With Sequential Manual Transaxle) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 ENGINE PERFORMANCE System & Component Testing - 4-Cylinder

Fig. 155: Identifying Terminals & Testing Accelerator Pedal Position Sensor (MR2 With Sequential Manual Transaxle) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Prius

WARNING: Read service precautions before proceeding with service procedure. See SERVICE PRECAUTIONS . 1. Electronic Throttle Control System (ETCS) is used for controlling idle speed. ETCS consists of throttle body, accelerator pedal position sensor, Throttle Position (TP) sensor, throttle control motor, Hybrid Vehicle Control Electronic Control Unit (HV ECU) and Engine Control Module (ECM). 2. To inspect ETCS operation, ensure ignition is off. Disconnect electrical connector at throttle control motor on throttle body. See Fig. 156 .

2002 ENGINE PERFORMANCE System & Component Testing - 4-Cylinder

Fig. 156: Locating Electronic Throttle Control System Components On Throttle Body & Accelerator Pedal Position Sensor (Prius) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 3. To test TP sensor operation, connect Toyota hand-held tester to data link connector No. 3 at driver's side of instrument panel. See Fig. 15 . Turn ignition on. Hand-held tester is used to read throttle valve opening which is displayed as a percentage. 4. Rotate throttle linkage to full throttle while reading throttle valve opening on hand-held tester which is accessed by THROTTLE POS under CURRENT DATA. Throttle valve opening should be at 60 percent or more. If throttle valve opening is at least 60 percent, go to next step. If throttle valve opening is not at least 60 percent, problem may exist in TP sensor, wiring circuit or ECM. Go to step 10 for testing of TP sensor. If necessary to check wiring between ECM and TP sensor, see WIRING DIAGRAMS article. ECM is located behind glove box. For illustration of ECM location, see THEORY & OPERATION article. 5. Turn ignition off. Reinstall electrical connector at throttle control motor. It is necessary to put transit in inspection mode so engine will run continuously. To put transit in inspection mode, perform the following steps within 60 seconds: Ensure ignition is off and then turn ignition on. Ensure transaxle is in Park and then fully depress accelerator pedal 2 times. Place transaxle in Neutral and then fully depress accelerator pedal 2 times. Place transaxle back in Park and then fully depress accelerator pedal 2 times. 6. Check that master warning light on instrument cluster at center of instrument panel is flashing to indicate inspection mode operation. See Fig. 140 . Master warning light may also be referred to as hybrid system error warning light. Turn ignition switch to START position to start engine. Engine will now start and run continuously.

2002 ENGINE PERFORMANCE System & Component Testing - 4-Cylinder

7. Warm engine to normal operating temperature. To check charging rate of High Voltage (HV) battery, apply brake and place shift lever in Drive and check that engine shuts off. If engine shuts off, go to next step. If engine does not shut off, charging rate of HV battery may be low. Place shift lever in Park and allow engine to run for a while to charge the HV battery. After engine has ran for a while, place shift lever in Drive and check that engine shuts off. If engine now shuts off, go to next step. If engine does not shut off, it may be necessary to place shift lever in Park and allow engine to run for a while to charge the HV battery. 8. With engine idling, turn A/C switch to ON and OFF positions while noting engine idle speed. Idle speed should be 950-1050 RPM with A/C switch in OFF position and 1150-1250 RPM with A/C switch in ON position. If idle speed is not as specified, go to next step. If idle speed is as specified, shut engine off. Remove hand-held tester. 9. To test throttle control motor, disconnect electrical connector for throttle control motor. See Fig. 156 . Using ohmmeter, check resistance between terminals No. 1 and 2 on electrical connector for throttle control motor. See Fig. 157 . Resistance should be .3-100.0 ohms at 68F (20C). If resistance is within specification, reinstall electrical connector. Go to next step. If resistance is not within specification, replace throttle body with throttle control motor as an assembly. See THROTTLE BODY under FUEL SYSTEMS in REMOVAL, OVERHAUL & INSTALLATION - 4-CYLINDER article. 10. To test TP sensor, disconnect electrical connector at TP sensor. See Fig. 156 . Using ohmmeter, check resistance between terminals E2 and VC on TP sensor. See Fig. 158 . Resistance should be 1200-3200 ohms at 68F (20C). If resistance is within specification, reinstall electrical connector. Go to next step. If resistance is not within specification, replace TP sensor. See THROTTLE BODY under FUEL SYSTEMS in REMOVAL, OVERHAUL & INSTALLATION - 4-CYLINDER article. 11. It may be necessary to check accelerator pedal position sensor. See ACCELERATOR PEDAL POSITION SENSOR under ENGINE SENSORS & SWITCHES. If TP sensor, throttle control motor and accelerator pedal position sensor are okay, but ETCS does not operate properly, it may be necessary to check wiring between ECM and TP sensor, ECM and throttle control motor, ECM and HV ECU. See WIRING DIAGRAMS article. ECM is located behind glove box. HV ECU is located below carpet on floor panel, just below passenger's side of instrument panel. For illustration of ECM location, see THEORY & OPERATION article.

2002 ENGINE PERFORMANCE System & Component Testing - 4-Cylinder

Fig. 158: Identifying Terminals & Testing Throttle Position Sensor (Prius) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Tacoma

1. Check that throttle linkage moves freely at throttle body. To check vacuum supply at throttle body, start engine and allow engine to idle. Note vacuum port location on throttle body. See Fig. 159 . 2. Check that vacuum and no vacuum exist at specified vacuum ports on throttle body with engine idling and with engine at more than idle. See THROTTLE BODY VACUUM SUPPLY table. Repair or replace components if vacuum supply is not as designated. THROTTLE BODY VACUUM SUPPLY Vacuum Port Engine Idling E No Vacuum P R
(1) With engine at 3500 RPM.

Engine At More Than Idle

(1) Vacuum (1) Vacuum (1) Vacuum

Vacuum No Vacuum

2002 ENGINE PERFORMANCE System & Component Testing - 4-Cylinder

Fig. 159: Identifying Vacuum Ports On Throttle Body (Tacoma) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

IGNITION SYSTEMS
NOTE: For basic ignition checks, see IGNITION SYSTEMS in BASIC DIAGNOSTIC PROCEDURES - 4-CYLINDER article.

TIMING CONTROL SYSTEMS

Knock Sensor

See KNOCK SENSOR under ENGINE SENSORS & SWITCHES.

EMISSION SYSTEMS & SUB-SYSTEMS

NOTE: For emission system component location, refer to illustrations. See Fig. 160 Fig. 167 . On Camry and Highlander, illustration was not available from manufacturer.

2002 ENGINE PERFORMANCE System & Component Testing - 4-Cylinder

Fig. 160: Locating Emission System Components (Camry Solara) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 161: Locating Emission System Components (Celica) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 162: Locating Emission System Components (Corolla) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 ENGINE PERFORMANCE System & Component Testing - 4-Cylinder

1. Remove cap and filter from top of EGR vacuum modulator. See Fig. 167 . Ensure filter is clean and in good condition. Clean filter with compressed air (if necessary). 2. Reinstall filter and cap. Ensure filter is installed in EGR vacuum modulator with coarse side facing upward, away from EGR vacuum modulator. Using 3-way connector, install vacuum gauge in vacuum hose between top of EGR valve and EGR vacuum modulator. Perform STEP 1 in illustration. See Fig. 168 . Start engine. Ensure engine idles smoothly to ensure proper seating of EGR valve. Shut engine off. 3. Connect Toyota hand-held tester or scan tool to data link connector No. 3 at driver's side of instrument panel. See Fig. 17 . Hand-held tester or scan tool is used to read engine RPM. To test operation of EGR Vacuum Switching Valve (VSV) with engine cold, ensure engine coolant temperature is less than 122F (50C). Start engine. Increase and maintain engine speed at 3500 RPM. Ensure no vacuum reading is obtained on vacuum gauge with engine speed at 3500 RPM and EGR pipe is not hot. 4. To test operation of EGR VSV and EGR vacuum modulator. Shut engine off. This test procedure may be performed by using Toyota hand-held tester to operate EGR VSV, or by connecting vacuum hose from port "Q" on EGR vacuum modulator to EGR valve. If using hand-held tester, go to next step. If hand-held tester is not available, go to step 6 . 5. Select ACTIVE TEST MODE on hand-held tester so EGR VSV is closed. Start engine. Operate engine at 3500 RPM. Ensure a low vacuum reading is obtained on vacuum gauge with engine speed at 3500 RPM. Shut engine off. Remove hand-held tester, vacuum gauge and reconnect vacuum hoses. Go to step 8 . 6. Remove 3-way connector and small vacuum hose between port "Q" (single port) on EGR vacuum modulator and EGR valve. Perform STEP 2 in illustration. See Fig. 168 . This 3-way connector and small vacuum hose goes from EGR valve and EGR vacuum modulator to EGR VSV. Install plug in vacuum hose to EGR VSV. 7. Connect vacuum hose from port "Q" on EGR vacuum modulator directly to EGR valve. See Fig. 169 . This will by-pass EGR VSV. Start engine. Operate engine at 3500 RPM. Ensure a low vacuum reading is obtained on vacuum gauge with engine speed at 3500 RPM. Shut engine off. Remove vacuum gauge and reconnect vacuum hoses. Go to next step. 8. To check EGR valve operation, remove and plug vacuum hose at EGR valve. Start engine. Using vacuum pump, apply vacuum directly to EGR valve with engine idling. Engine should run rough or stall. If EGR system does not operate as described, each individual component should be tested.

2002 ENGINE PERFORMANCE System & Component Testing - 4-Cylinder

REMOVAL, OVERHAUL & INSTALLATION - 4-CYLINDER article. 2. Inspect EGR valve for restricted passages caused by carbon deposits. Using vacuum pump, apply vacuum directly to EGR valve and ensure valve opens. Release vacuum and ensure valve closes. Replace EGR valve if defective. HYDROCARBON ADSORBER CATALYST SYSTEM (PRIUS) NOTE: Hydrocarbon adsorber catalyst system may also be referred to as HCAC system. WARNING: Read service precautions before proceeding with service procedure. See SERVICE PRECAUTIONS .
Hydrocarbon Adsorber Catalyst System Check

1. Hydrocarbon adsorber may also be referred to as HC adsorber. Start engine and warm engine to normal operating temperature. Shut engine off. If Toyota hand-held tester is available, go to next step. If Toyota hand-held tester is not available, go to step 3 . 2. Connect hand-held tester to data link connector No. 3 at driver's side of instrument panel. See Fig. 15 . Start engine. Turn hand-held tester on. Select proper mode on hand-held tester to operate HCAC Vacuum Switching Valve (VSV). Go to step 4 . 3. Disconnect electrical connector at HCAC Vacuum Switching Valve (VSV). See Fig. 171 . HCAC VSV is located on bracket bolted to timing chain end of engine and uses a Brown 2-pin electrical connector with Black and Black/White wires. Apply battery voltage and ground to electrical terminals on HCAC VSV to operate HCAC VSV. See Fig. 172 . Start engine. Go to next step. 4. With engine idling and HCAC VSV operating, check that rod on actuator is pulled inward and that by-pass valve moves. Actuator and by-pass valve are located at front of three-way catalytic converter on exhaust pipe. See Fig. 173 . If rod on actuator is not pulled inward and by-pass valve does not move, shut engine off. Go to next step. If rod on actuator is pulled inward and by-pass valve moves, HCAC system is operating properly. Shut engine off. Reinstall electrical connector at HCAC VSV (if removed) and disconnect hand-held tester (if used). 5. Check vacuum hose and line to HCAC VSV. If vacuum hose and line are okay, check operation of actuator for HCAC system and HCAC VSV. See ACTUATOR FOR HCAC SYSTEM & BY-PASS VALVE and HCAC VACUUM SWITCHING VALVE . If vacuum hose or line are defective, replace components as necessary and recheck system operation.

2002 ENGINE PERFORMANCE System & Component Testing - 4-Cylinder

Fig. 174: Testing Hydrocarbon Adsorber Catalyst Vacuum Switching Valve (Prius) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. FUEL EVAPORATIVE SYSTEM NOTE: Fuel evaporative system is referred to as fuel EVAP system and may contain different components depending on application. See Fig. 160 -Fig. 167 . When testing fuel EVAP system components, use proper illustration to determine component location.

2002 ENGINE PERFORMANCE System & Component Testing - 4-Cylinder

NOTE:

On all models, an On-Board Refilling Vapor Recovery (ORVR) system is used to recover fuel vapors into charcoal canister that are generated during refueling. ORVR system consists of fuel inlet pipe, overfill check valve, cutoff valve and charcoal canister. See Fig. 160 -Fig. 167 . Overfill check valve may also be referred to as On-Board Refueling Vapor Recovery Overfill Check Valve (ORVR-OCKV) or fill check valve. Cut-off valve may also be referred to On-Board Refueling Vapor Recovery Cut-Off Valve (ORVR-COV). For testing of fuel EVAP system and ORVR system, see appropriate FUEL EVAP SYSTEM TEST. Charcoal canister may also be referred to as EVAP canister. Manufacturer provides testing information for testing airtightness of fuel tank and components along with testing of charcoal canister and fuel EVAP system.

NOTE:

Fuel EVAP System Test (Camry & Highlander)

NOTE:

Manufacturer provides testing information for testing airtightness of fuel tank and components along with testing of charcoal canister and fuel EVAP system.

1. Inspect all fuel EVAP system lines and connections for sharp bends or damage. Fuel inlet pipe may also be referred to as fuel filler pipe. Inspect fuel inlet pipe for cracks, damage or fuel leakage. Inspect fuel tank cap for cracks or deformed gasket. Replace components if defective or damaged. 2. Start engine and warm engine to normal operating temperature. Shut engine off. Connect vacuum gauge from EVAP System Test Kit (00002-6872A) to EVAP service port. EVAP service port is located in engine compartment, in purge vacuum hose for EVAP system, near air cleaner assembly. EVAP service port contains a Green label for identification. 3. Operate EVAP Vacuum Switching Valve (VSV). If Toyota hand-held tester is available to operate EVAP VSV, go to next step. If Toyota hand-held tester is not available to operate EVAP VSV, go to step 5 . 4. Connect hand-held tester to data link connector No. 3 at driver's side of instrument panel. See Fig. 8 and Fig. 13 . . Start engine. Turn hand-held tester on. Select ACTIVE TEST MODE on hand-held tester. Using hand-held tester manufacturer's instructions, activate EVAP VSV. Go to step 6 . 5. Disconnect electrical connector at EVAP VSV. On Camry, EVAP VSV is located near rear of air cleaner housing and contains Blue or Black 2-pin electrical connector with Black/White and Black/Red wires. On Highlander, EVAP VSV is located on rear of air cleaner housing and contains Blue 2-pin electrical connector with Black/White and Black/Red wires. On all models, using jumper wires, connect battery voltage and ground to electrical terminals on EVAP VSV to operate EVAP VSV. Start engine. Go to next step. 6. Check vacuum reading on vacuum gauge with engine idling. Vacuum reading should be .368-19.713 in. Hg (5.00-268.00 in. H2O) for over 5 seconds. If vacuum reading is within specification, go to next step. If vacuum reading is not within specification, check for loose or restricted vacuum hose to EVAP service port, or for malfunctioning EVAP VSV. To check EVAP VSV operation, see EVAP VACUUM SWITCHING VALVE . 7. Shut engine off. If using hand-held tester to operate EVAP VSV, stop operation of EVAP VSV. Remove hand-held tester. Go to next step. If connecting battery voltage to EVAP VSV to operate EVAP VSV, disconnect jumper wires and reconnect electrical connector on EVAP VSV. Go to next step.

2002 ENGINE PERFORMANCE System & Component Testing - 4-Cylinder

8. Disconnect vacuum gauge from EVAP service port. Connect pressure gauge to EVAP service port. Install hose crimper on air drain hose near charcoal canister. Perform STEP 1 in illustration. See Fig. 175 and Fig. 176 . Charcoal canister is located near the fuel tank. 9. Apply 13.5-15.5 in. H2O of pressure to EVAP service port. After 2 minutes of applying pressure, pressure should be 7.7-8.8 in. H2O. If pressure is within specification, go to next step. If pressure cannot be maintained, remove hose crimper. Check for disconnected vacuum hose between EVAP VSV, charcoal canister and fuel tank. If vacuum hose is properly installed on EVAP VSV, charcoal canister and fuel tank, check for stuck open EVAP VSV. To check EVAP VSV operation, see EVAP VACUUM SWITCHING VALVE . 10. With pressure still applied at EVAP service port, remove fuel tank cap and note pressure reading. Pressure should decrease when fuel tank cap is removed. If pressure decreases when fuel tank cap is removed, remove pressure gauge and hose crimper. Go to next step. If pressure does not decrease when fuel tank cap is removed, remove pressure gauge and hose crimper. Check for restricted vacuum hose between EVAP service port, charcoal canister and fuel tank. Repair or replace vacuum hose as necessary. 11. To check airtightness of fuel tank and fuel inlet pipe, disconnect EVAP line hose from charcoal canister. Perform STEP 2 in illustration. See Fig. 175 and Fig. 176 . Apply .58 psi (.040 kg/cm2 ) air pressure to EVAP line hose so pressure inside fuel tank is .58 psi (.040 kg/cm2 ). Check that pressure inside fuel tank holds steady for one minute. 12. If pressure inside fuel tank holds steady for one minute, reinstall EVAP line hose on charcoal canister. Go to next step. If pressure inside fuel will not hold steady for one minute, check for leaking hoses or pipes at fuel tank and fuel inlet pipe, or for leaks at fuel tank or installed components on fuel tank. If no leaks exist, replace fuel tank and fuel inlet pipe. Reinstall EVAP line hose on charcoal canister. Go to next step. NOTE: Overfill check valve may also be referred to as fill check valve. Cut-off valve may also be referred to as fuel cut-off valve.

13. To check overfill check valve and cut-off valve, disconnect purge line hose and EVAP line hose from charcoal canister and install cap on air drain hose. Perform STEP 3 in illustration. See Fig. 175 and Fig. 176 . 14. Apply .58 psi (.040 kg/cm2 ) air pressure to purge line hose fitting on charcoal canister. Perform STEP 3 in illustration. See Fig. 175 and Fig. 176 . Ensure air flows from EVAP line hose when air pressure is applied to purge line hose fitting on charcoal canister. If fuel tank is full of fuel, air may not flow from EVAP line hose, as overfill check valve may be closed. Ensure fuel tank is not full of fuel when checking for airflow at EVAP line hose. 15. If air flows from EVAP line hose, go to next step. If air does not flow from EVAP line hose, check for restrictions in EVAP line hose and vent line hose. If any hose is restricted, replace hose and recheck operation. If hoses are not restricted, replace overfill check valve and cut-off valve located on top of fuel tank. 16. Reinstall purge line hose and EVAP line hose on charcoal canister. To check air inlet line, disconnect air inlet line hose from charcoal canister. Perform STEP 4 in illustration. See Fig. 175 and Fig. 176 . Apply air pressure to air inlet line hose. Air should flow through air inlet line hose. If air flows through air inlet line hose, go to next step. If air does not flow through air inlet line hose, check for restricted air inlet line hose or air inlet line. 17. To check charcoal canister, disconnect necessary electrical connectors and components for removal of charcoal canister. Remove retaining bolts/nuts and charcoal canister. Inspect charcoal canister for cracks or damage. If charcoal canister is okay, go to next step. If charcoal canister is defective, replace

2002 ENGINE PERFORMANCE System & Component Testing - 4-Cylinder

charcoal canister. 18. Install cap on vent port on charcoal canister. See Fig. 177 . Apply .26 psi (.018 kg/cm2 ) air pressure to EVAP port while holding purge port closed. See Fig. 177 . Ensure air flows freely from air drain port. 19. Apply .26 psi (.018 kg/cm2 ) air pressure to EVAP port while holding air drain port and purge port closed. See Fig. 177 . Ensure air does not flow for air inlet port. 20. Using vacuum pump, apply 1.01 in. Hg of vacuum to purge port. See Fig. 177 . Ensure vacuum does not decrease when air inlet port is closed and that vacuum decreases when air inlet port is opened. 21. While holding air inlet port closed, use vacuum pump to apply 1.01 in. Hg of vacuum to EVAP port. See Fig. 177 . Ensure air flows into purge port. Remove cap from vent port. Replace charcoal canister if defective. 22. Reinstall charcoal canister. If fuel EVAP system operates properly, it may be necessary to check operation of EVAP VSV, canister closed valve Vacuum Switching Valve (VSV) and pressure switching valve Vacuum Switching Valve (VSV). See EVAP VACUUM SWITCHING VALVE , CANISTER CLOSED VALVE VACUUM SWITCHING VALVE and PRESSURE SWITCHING VALVE VACUUM SWITCHING VALVE . Manufacturer does provide individual component testing for vapor pressure sensor. If problem exists with vapor pressure sensor, a Diagnostic Trouble Code (DTC) may be stored in Engine Control Module (ECM). See TESTING PROCEDURE under SELF-DIAGNOSTIC SYSTEM in appropriate SELF-DIAGNOSTICS article for retrieving of DTCs.

2002 ENGINE PERFORMANCE System & Component Testing - 4-Cylinder

Fig. 175: Testing Fuel EVAP System & Lines (Camry, Camry Solara & Corolla) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 ENGINE PERFORMANCE System & Component Testing - 4-Cylinder

Fig. 177: Identifying Typical Charcoal Canister Ports (Camry, Camry Solara, Celica, Corolla, Highlander, MR2, RAV4 & Tacoma) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Fuel EVAP System Test (Camry Solara, Celica, Corolla, MR2, RAV4 & Tacoma)

NOTE:

Manufacturer provides testing information for testing airtightness of fuel tank and components along with testing of charcoal canister and fuel EVAP system.

1. Inspect all fuel EVAP system lines and connections for sharp bends or damage. Fuel inlet pipe may also be referred to as fuel filler pipe. Inspect fuel inlet pipe for cracks, damage or fuel leakage. Inspect fuel tank cap for cracks or deformed gasket. Replace components if defective or damaged. 2. Start engine and warm engine to normal operating temperature. Shut engine off. Connect vacuum gauge from EVAP System Test Kit (00002-6872A) to EVAP service port. EVAP service port is located in engine compartment, in purge vacuum hose for EVAP system. See Fig. 160 -Fig. 162 , Fig. 164 , Fig. 166 and Fig. 167 . 3. Operate EVAP Vacuum Switching Valve (VSV). If Toyota hand-held tester is available to operate EVAP VSV, go to next step. If Toyota hand-held tester is not available to operate EVAP VSV, go to step 5 . 4. Connect hand-held tester to data link connector No. 3 at driver's side of instrument panel. See Fig. 9 Fig. 11 , Fig. 14 Fig. 16 and Fig. 17 . Start engine. Turn hand-held tester on. Select ACTIVE TEST MODE on hand-held tester. Using hand-held tester manufacturer's instructions, activate EVAP VSV. Go to step 6 . 5. Disconnect electrical connector at EVAP VSV. See EVAP VSV LOCATION table. See Fig. 160 Fig. 162 , Fig. 164 , Fig. 166 and Fig. 167 . Using jumper wires, connect battery voltage and ground to electrical terminals on EVAP VSV to operate EVAP VSV. Start engine. Go to next step.

2002 ENGINE PERFORMANCE System & Component Testing - 4-Cylinder

EVAP VSV LOCATION Application Location Camry Solara On Air Intake Hose, Near Air Cleaner Assembly & Contains Black 2-Pin Electrical Connector With Black/White & Black/Red Wires Celica On Bracket At Rear Of Air Cleaner Housing & Contains Black 2-Pin Electrical Connector With Green/Orange & Black/White Wires Corolla On Bracket At Rear Of Air Cleaner Housing & Contains Black 2-Pin Electrical Connector With Blue/Black & Black Wires MR2 On Air Intake Hose, Near Air Cleaner Assembly & Contains Blue 2-Pin Electrical Connector With Black/Red & White Wires RAV4 On Air Intake Hose, Near Air Cleaner Assembly & Contains Black 2-Pin Electrical Connector With Black/Red & Pink Wires Tacoma On Bracket Bolted To Inside Of Driver's Side Front Fender Panel & Contains Black 2-Pin Electrical Connector With White/Green & White/Red Wires 6. Check vacuum reading on vacuum gauge with engine idling. Vacuum reading should be within specification for over 5 seconds. See VACUUM SPECIFICATIONS table. If vacuum reading is within specification, go to next step. If vacuum reading is not within specification, check for loose or restricted vacuum hose to EVAP service port, or for malfunctioning EVAP VSV. To check EVAP VSV operation, see EVAP VACUUM SWITCHING VALVE . VACUUM SPECIFICATIONS Application Camry Solara, Celica, Corolla & Tacoma MR2 & RAV4

In. Hg (In. H20) .368-19.713 (5.00-268.00) .368-3.678 (5.00-50.00)

7. Shut engine off. If using hand-held tester to operate EVAP VSV, stop operation of EVAP VSV. Remove hand-held tester. Go to next step. If connecting battery voltage to EVAP VSV to operate EVAP VSV, disconnect jumper wires and reconnect electrical connector on EVAP VSV. Go to next step. 8. Disconnect vacuum gauge from EVAP service port. Connect pressure gauge to EVAP service port. Install hose crimper on air drain hose near charcoal canister. Perform STEP 1 in illustration. See Fig. 175 and Fig. 178 -Fig. 181 . On MR2, hose crimper should be installed at White-colored area on air drain hose. On RAV4, hose crimper should be installed at Yellow-colored area on air drain hose. On all models, charcoal canister is located near fuel tank. See Fig. 160 -Fig. 162 , Fig. 164 , Fig. 166 and Fig. 167 . 9. Apply 13.5-15.5 in. H2O of pressure to EVAP service port. After 2 minutes of applying pressure, pressure should be 7.7-8.8 in. H2O. If pressure is within specification, go to next step. If pressure

2002 ENGINE PERFORMANCE System & Component Testing - 4-Cylinder

cannot be maintained, remove hose crimper. Check for disconnected vacuum hose between EVAP VSV, charcoal canister and fuel tank. If vacuum hose is properly installed on EVAP VSV, charcoal canister and fuel tank, check for stuck open EVAP VSV. To check EVAP VSV operation, see EVAP VACUUM SWITCHING VALVE . 10. With pressure still applied at EVAP service port, remove fuel tank cap and note pressure reading. Pressure should decrease when fuel tank cap is removed. If pressure decreases when fuel tank cap is removed, remove pressure gauge and hose crimper. Go to next step. If pressure does not decrease when fuel tank cap is removed, remove pressure gauge and hose crimper. Check for restricted vacuum hose between EVAP service port, charcoal canister and fuel tank. Repair or replace vacuum hose as necessary. 11. To check airtightness of fuel tank and fuel inlet pipe, disconnect EVAP line hose from charcoal canister. Perform STEP 2 in illustration. See Fig. 175 and Fig. 178 -Fig. 181 . Apply .58 psi (.040 kg/cm2 ) air pressure to EVAP line hose so pressure inside fuel tank is .58 psi (.040 kg/cm2 ). Check that pressure inside fuel tank holds steady for one minute. 12. If pressure inside fuel tank holds steady for one minute, reinstall EVAP line hose on charcoal canister. Go to next step. If pressure inside fuel will not hold steady for one minute, check for leaking hoses or pipes at fuel tank and fuel inlet pipe, or for leaks at fuel tank or installed components on fuel tank. If no leaks exist, replace fuel tank and fuel inlet pipe. Reinstall EVAP line hose on charcoal canister. Go to next step. NOTE: Overfill check valve may also be referred to as fill check valve. Cut-off valve may also be referred to as fuel cut-off valve.

13. To check overfill check valve and cut-off valve, disconnect purge line hose and EVAP line hose from charcoal canister. Install cap on air drain hose or cap on air drain hose fitting on charcoal canister. Perform STEP 3 in illustration. See Fig. 175 and Fig. 178 -Fig. 181 . 14. Apply .58 psi (.040 kg/cm2 ) air pressure to purge line hose fitting on charcoal canister. Perform STEP 3 in illustration. See Fig. 175 and Fig. 178 -Fig. 181 . Ensure air flows from EVAP line hose when air pressure is applied to purge line hose fitting on charcoal canister. If fuel tank is full of fuel, air may not flow from EVAP line hose, as overfill check valve may be closed. Ensure fuel tank is not full of fuel when checking for airflow at EVAP line hose. 15. If air flows from EVAP line hose, go to next step. If air does not flow from EVAP line hose, check for restrictions in EVAP line hose and vent line hose. If any hose is restricted, replace hose and recheck operation. If hoses are not restricted, replace overfill check valve and cut-off valve (if equipped). Overfill check valve and cut-off valve (if equipped) are located on top of fuel tank. See Fig. 160 -Fig. 162 , Fig. 164 , Fig. 166 and Fig. 167 . 16. Reinstall purge line hose and EVAP line hose on charcoal canister. To check air inlet line, disconnect air inlet line hose from charcoal canister. Perform STEP 4 in illustration. See Fig. 175 and Fig. 178 Fig. 181 . Apply air pressure to air inlet line hose. Air should flow through air inlet line hose. If air flows through air inlet line hose, go to next step. If air does not flow through air inlet line hose, check for restricted air inlet line hose or air inlet line. 17. To check charcoal canister, remove necessary components for access to charcoal canister. Disconnect necessary electrical connectors for removal of charcoal canister. Disconnect purge line hose, EVAP line hose and air inlet line hose from charcoal canister if not previously done. 18. Push connector on vent line hose toward charcoal canister and pinch both sides of retainer on connector, and then disconnect vent line hose with connector from charcoal canister. See Fig. 182 and Fig. 183 . 19. Remove vapor pressure sensor bolts/nut (if equipped). Remove retaining bolts/nuts and charcoal

2002 ENGINE PERFORMANCE System & Component Testing - 4-Cylinder

canister. Inspect charcoal canister for cracks or damage. If charcoal canister is okay, go to next step. If charcoal canister is defective, replace charcoal canister. 20. On Camry Solara, Celica, MR2 and RAV4 install cap on vent port on charcoal canister. See Fig. 177 . On Corolla and Tacoma, install hose and cap on vent port. See Fig. 177 . On all models, apply .26 psi (.018 kg/cm2 ) air pressure to EVAP port while holding purge port closed. See Fig. 177 . Ensure air flows freely from air drain port. 21. Apply .26 psi (.018 kg/cm2 ) air pressure to EVAP port while holding air drain port and purge port closed. See Fig. 177 . Ensure air does not flow from air inlet port. 22. Using vacuum pump, apply 1.01 in. Hg of vacuum to purge port. See Fig. 177 . Ensure vacuum does not decrease when air inlet port is closed and that vacuum decreases when air inlet port is opened. 23. While holding air inlet port closed, use vacuum pump to apply 1.01 in. Hg of vacuum to EVAP port. See Fig. 177 . Ensure air flows into purge port. Remove hose (if used) and cap from vent port. Replace charcoal canister if defective. 24. Reinstall charcoal canister. If fuel EVAP system operates properly, it may be necessary to check operation of EVAP VSV, canister closed valve Vacuum Switching Valve (VSV), pressure switching valve Vacuum Switching Valve (VSV) and vapor pressure sensor. See EVAP VACUUM SWITCHING VALVE , CANISTER CLOSED VALVE VACUUM SWITCHING VALVE , PRESSURE SWITCHING VALVE VACUUM SWITCHING VALVE and appropriate VAPOR PRESSURE SENSOR procedure.

2002 ENGINE PERFORMANCE System & Component Testing - 4-Cylinder

Fig. 183: Disconnecting Typical Vent Line Hose & Connector At Charcoal Canister (Celica, Corolla, MR2, RAV4 & Tacoma) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Fuel EVAP System Test (ECHO)

NOTE:

Manufacturer provides testing information for testing airtightness of fuel tank and components along with testing of charcoal canister and fuel EVAP system.

1. Inspect all fuel EVAP system lines and connections for sharp bends or damage. Fuel inlet pipe may also be referred to as fuel filler pipe. Inspect fuel inlet pipe for cracks, damage or fuel leakage. Inspect fuel tank cap for cracks or deformed gasket. Replace components if defective or damaged. 2. Start engine and warm engine to normal operating temperature. Shut engine off. Connect vacuum gauge from EVAP System Test Kit (00002-6872A) to EVAP service port. EVAP service port is located in engine compartment, in purge vacuum hose for EVAP system. See Fig. 163 . 3. Operate EVAP Vacuum Switching Valve (VSV). If Toyota hand-held tester is available to operate EVAP VSV, go to next step. If Toyota hand-held tester is not available to operate EVAP VSV, go to

2002 ENGINE PERFORMANCE System & Component Testing - 4-Cylinder

4.

5.

6.

7.

8.

9.

10.

step 5 . Connect hand-held tester to data link connector No. 3 at driver's side of instrument panel. See Fig. 12 . Start engine. Turn hand-held tester on. Select ACTIVE TEST MODE on hand-held tester. Using hand-held tester manufacturer's instructions, activate EVAP VSV. Go to step 6 . Disconnect electrical connector at EVAP VSV. EVAP VSV is located on bracket at side of air cleaner housing and contains Blue 2-pin electrical connector with Black/Yellow and White/Green wires. See Fig. 163 . Using jumper wires, connect battery voltage and ground to electrical terminals on EVAP VSV to operate EVAP VSV. Start engine. Go to next step. Check vacuum reading on vacuum gauge with engine idling. Vacuum reading should be .368-19.713 in. Hg (5.00-268.00 in. H2O) for over 5 seconds. If vacuum reading is within specification, go to next step. If vacuum reading is not within specification, check for loose or restricted vacuum hose to EVAP service port, or for malfunctioning EVAP VSV. To check EVAP VSV operation, see EVAP VACUUM SWITCHING VALVE . Shut engine off. If using hand-held tester to operate EVAP VSV, stop operation of EVAP VSV. Leave hand-held tester connected to data link connector No. 3 and go to next step. If connecting battery voltage to EVAP VSV to operate EVAP VSV, disconnect jumper wires and reconnect electrical connector on EVAP VSV. Go to next step. Disconnect vacuum gauge from EVAP service port. Connect pressure gauge to EVAP service port. Operate Canister Closed Valve Vacuum Switching Valve (CCV VSV). If Toyota hand-held tester is available to operate CCV VSV, go to next step. If Toyota hand-held tester is not available to operate CCV VSV, go to step 10 . With hand-held tester still connected to DLC No. 3, turn ignition on and then turn hand-held tester on. DO NOT start engine. Select ACTIVE TEST MODE on hand-held tester. Using hand-held tester manufacturer's instructions, activate CCV VSV. Go to step 11 . Install hose crimper on air drain hose near charcoal canister. Charcoal canister is located near fuel tank. See Fig. 163 . Perform STEP 1 in illustration. See Fig. 184 . Go to next step. NOTE: If using hand-held tester to activate CCV VSV, this step must be completed within 10 minutes after CCV VSV was activated or CCV VSV will be reset.

11. Apply 13.5-15.5 in. H2O of pressure to EVAP service port. After 2 minutes of applying pressure, pressure should be 7.7-8.8 in. H2O. If pressure is within specification, go to next step. If pressure cannot be maintained, check for disconnected vacuum hose between EVAP VSV, charcoal canister and fuel tank. If vacuum hose is properly installed on EVAP VSV, charcoal canister and fuel tank, check for stuck open EVAP VSV. To check EVAP VSV operation, see EVAP VACUUM SWITCHING VALVE . 12. With pressure still applied at EVAP service port, remove fuel tank cap and note pressure reading. Pressure should decrease when fuel tank cap is removed. If pressure decreases when fuel tank cap is removed and hand-held tester was used to activate CCV VSV, turn ignition off. Remove pressure gauge and hand-held tester. Go to next step. If pressure decreases when fuel tank cap is removed and hand-held tester was not used to operate CCV VSV, remove hose crimper and pressure gauge. Go to next step. On all applications, if pressure does not decrease when fuel tank cap is removed, remove pressure gauge and hose crimper. Check for restricted vacuum hose between EVAP service port, charcoal canister and fuel tank. Repair or replace vacuum hose as necessary. 13. To check airtightness of fuel tank and fuel inlet pipe, disconnect EVAP line hose from charcoal canister by pinching both sides of connector together. Perform STEP 2 in illustration. See Fig. 184 . Apply .58 psi (.040 kg/cm2 ) air pressure to EVAP line hose so pressure inside fuel tank is .58 psi

2002 ENGINE PERFORMANCE System & Component Testing - 4-Cylinder

(.040 kg/cm2 ). Check that pressure inside fuel tank holds steady for one minute. 14. If pressure inside fuel tank holds steady for one minute, reinstall EVAP line hose on charcoal canister. Go to next step. If pressure inside fuel will not hold steady for one minute, check for leaking hoses or pipes at fuel tank and fuel inlet pipe, or for leaks at fuel tank or installed components on fuel tank. If no leaks exist, replace fuel tank and fuel inlet pipe. Reinstall EVAP line hose on charcoal canister. Go to next step. NOTE: Overfill check valve may also be referred to as fill check valve. Cut-off valve may also be referred to as fuel cut-off valve.

15. To check overfill check valve and cut-off valve, disconnect purge line hose and EVAP line hose from charcoal canister and install cap on air drain hose. Perform STEP 3 in illustration. See Fig. 184 . 16. Apply .58 psi (.040 kg/cm2 ) air pressure to purge line hose fitting on charcoal canister. Perform STEP 3 in illustration. See Fig. 184 . Ensure air flows from EVAP line hose when air pressure is applied to purge line hose fitting on charcoal canister. If fuel tank is full of fuel, air may not flow from EVAP line hose, as overfill check valve may be closed. Ensure fuel tank is not full of fuel when checking for airflow at EVAP line hose. 17. If air flows from EVAP line hose, go to next step. If air does not flow from EVAP line hose, check for restrictions in EVAP line hose and vent line hose. If any hose is restricted, replace hose and recheck operation. If hoses are not restricted, replace overfill check valve and cut-off valve located on top of fuel tank. See Fig. 163 . 18. Reinstall purge line hose and EVAP line hose on charcoal canister. To check air inlet line, disconnect air inlet line hose from charcoal canister. Perform STEP 4 in illustration. See Fig. 184 . Apply air pressure to air inlet line hose. Air should flow through air inlet line hose. If air flows through air inlet line hose, go to next step. If air does not flow through air inlet line hose, check for restricted air inlet line hose or air inlet line. 19. To check charcoal canister, disconnect necessary electrical connectors and components for removal of charcoal canister. Disconnect purge line hose, EVAP line hose and air inlet line hose from charcoal canister if not previously done. 20. Push connector on vent line hose toward charcoal canister, pinch both sides of retainer on connector, and disconnect vent line hose with connector from charcoal canister. See Fig. 185 . 21. Remove retaining nuts and charcoal canister. Inspect charcoal canister for cracks or damage. If charcoal canister is okay, go to next step. If charcoal canister is defective, replace charcoal canister. 22. Install cap on vent port on charcoal canister. See Fig. 186 . Apply .26 psi (.018 kg/cm2 ) air pressure to EVAP port while holding purge port closed. See Fig. 186 . Ensure air flows freely from air drain port. 23. Apply .26 psi (.018 kg/cm2 ) air pressure to EVAP port while holding air drain port and purge port closed. See Fig. 186 . Ensure air does not flow from air inlet port. 24. Using vacuum pump, apply 1.01 in. Hg of vacuum to purge port. See Fig. 186 . Ensure vacuum does not decrease when air inlet port is closed and that vacuum decreases when air inlet port is opened. 25. While holding air inlet port closed, use vacuum pump to apply 1.01 in. Hg of vacuum to EVAP port. See Fig. 186 . Ensure air flows into purge port. Remove cap from vent port. Replace charcoal canister if defective. 26. Reinstall charcoal canister. If fuel EVAP system operates properly, it may be necessary to check operation of EVAP Vacuum Switching Valve (VSV), canister closed valve Vacuum Switching Valve (VSV) and vapor pressure sensor. See EVAP VACUUM SWITCHING VALVE , CANISTER CLOSED VALVE VACUUM SWITCHING VALVE and VAPOR PRESSURE SENSOR .

2002 ENGINE PERFORMANCE System & Component Testing - 4-Cylinder

Fig. 190: Identifying Ports On Charcoal Canister, Trap Filter & Fresh Air Valve (Prius) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Canister Closed Valve Vacuum Switching Valve (Camry, Camry Solara, Celica, Corolla, ECHO, Highlander, MR2, RAV4 & Tacoma)

1. Disconnect electrical connector at Canister Closed Valve Vacuum Switching Valve (CCV VSV). See Fig. 191 -Fig. 199 . Remove CCV VSV.

2002 ENGINE PERFORMANCE System & Component Testing - 4-Cylinder

NOTE:

On ECHO, charcoal canister must be removed for removal of CCV VSV. Charcoal canister is located near fuel tank. See Fig. 163 . For removal of CCV VSV, see CANISTER CLOSED VALVE VACUUM SWITCHING VALVE under EMISSION SYSTEMS & SUB-SYSTEMS in REMOVAL, OVERHAUL & INSTALLATION - 4-CYLINDER article.

2. Using ohmmeter, check that continuity exists between electrical terminals on CCV VSV and that resistance is within specification. See CANISTER CLOSED VALVE VACUUM SWITCHING VALVE RESISTANCE table. Replace CCV VSV if no continuity exists or resistance is not within specification. CANISTER CLOSED VALVE VACUUM SWITCHING VALVE RESISTANCE Application Ohms @ 68F (20C) Camry 24-30 (1) Camry Solara & ECHO Celica & Highlander Corolla, MR2 & RAV4 Tacoma 42 ohms at 248 F (120C). 3. Using ohmmeter, ensure no continuity exists between each electrical terminal and body of CCV VSV. Replace CCV VSV if continuity exists between electrical terminal and body of CCV VSV. 4. To test CCV VSV operation, apply air pressure to port "A". Ensure air flows from port "B". Perform STEP 1 in illustration. See Fig. 200 -Fig. 205 . 5. Apply battery voltage and ground to electrical terminals on CCV VSV. Apply air pressure to port "A". Ensure air does not flow from port "B". Perform STEP 2 in illustration. See Fig. 200 -Fig. 205 . Replace CCV VSV if defective. 24-30 25-30
(1)

(1) Resistance should be 25-30 ohms at 68F (20C) and 33-

2002 ENGINE PERFORMANCE System & Component Testing - 4-Cylinder

Fig. 194: Locating Canister Closed Valve Vacuum Switching Valve (Corolla) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 195: Locating Canister Closed Valve Vacuum Switching Valve (ECHO) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 ENGINE PERFORMANCE System & Component Testing - 4-Cylinder

Fig. 205: Testing Canister Closed Valve Vacuum Switching Valve (Tacoma) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Canister Closed Valve Vacuum Switching Valve (Prius)

WARNING: Read service precautions before proceeding with service procedure. See SERVICE PRECAUTIONS . 1. Manufacturer states to remove fuel tank for access to Canister Closed Valve Vacuum Switching Valve (CCV VSV) as it is mounted on top of fuel tank. See Fig. 165 . 2. Remove fuel tank. See FUEL PUMP under FUEL SYSTEMS in REMOVAL, OVERHAUL & INSTALLATION - 4-CYLINDER article for removal of fuel tank. Disconnect necessary hoses and electrical connectors for removal of CCV VSV and fresh air valve. Remove bolt and separate fresh air valve from CCV VSV. See Fig. 165 . Remove bolts for CCV VSV and remove CCV VSV along with trap filter. Remove bolts and separate trap filter from CCV VSV. 3. Using ohmmeter, check that continuity exists between electrical terminals on CCV VSV and that resistance is 25-30 ohms at 68F (20C). Replace CCV VSV if no continuity exists or resistance is not within specification. 4. Using ohmmeter, ensure no continuity exists between each electrical terminal and body of CCV VSV. Replace CCV VSV if continuity exists between electrical terminal and body of CCV VSV. 5. To test CCV VSV operation, apply air pressure to port "A". Ensure air flows from port "B". Perform STEP 1 in illustration. See Fig. 206 . 6. Apply battery voltage and ground to electrical terminals on CCV VSV. Apply air pressure to port "A". Ensure air does not flow from port "B". Perform STEP 2 in illustration. See Fig. 206 . Replace CCV VSV if defective. Reinstall CCV VSV and fuel tank.

2002 ENGINE PERFORMANCE System & Component Testing - 4-Cylinder

Individual component testing is not available from manufacturer. Manufacturer provides testing information for testing airtightness of fuel tank and components along with testing of charcoal canister, cut-off valve and fuel EVAP system. See appropriate FUEL EVAP SYSTEM TEST.
EVAP Vacuum Switching Valve (All Models)

WARNING: On Prius, read service precautions before proceeding with service procedure. See SERVICE PRECAUTIONS . 1. Remove EVAP Vacuum Switching Valve (VSV). See EVAP VACUUM SWITCHING VALVE LOCATION table. See Fig. 160 -Fig. 167 . EVAP VACUUM SWITCHING VALVE LOCATION Application Location Camry On Air Cleaner Housing & Contains Blue or Black 2-Pin Electrical Connector With Black/White & Black/Red Wires Camry Solara On Air Intake Hose, Near Air Cleaner Assembly & Contains Black 2-Pin Electrical Connector With Black/White & Black/Red Wires Celica On Bracket At Rear Of Air Cleaner Housing & Contains Black 2-Pin Electrical Connector With Green/Orange & Black/White Wires Corolla On Bracket At Rear Of Air Cleaner Housing & Contains Black 2-Pin Electrical Connector With Blue/Black & Black Wires ECHO On Bracket At Side Of Air Cleaner Housing & Contains Blue 2-Pin Electrical Connector With Black/Yellow & White/Green Wires Highlander On Rear Of Air Cleaner Housing & Contains Blue 2-Pin Electrical Connector With Black/White & Black/Red Wires MR2 On Air Intake Hose, Near Air Cleaner Assembly & Contains Blue 2-Pin Electrical Connector With Black/Red & White Wires Prius At Passenger's Side Front Corner Of Engine Compartment, Near Air Intake Hose & Contains Blue 2-Pin Electrical Connector With Red/Blue & Black Wires RAV4 On Air Intake Hose, Near Air Cleaner Assembly & Contains Black 2-Pin Electrical Connector With Black/Red & Pink Wires Tacoma On Bracket Bolted To Inside Of Driver's Side Front Fender Panel & Contains Black 2-Pin Electrical Connector With

2002 ENGINE PERFORMANCE System & Component Testing - 4-Cylinder

White/Green & White/Red Wires 2. Using ohmmeter, ensure continuity exists between electrical terminals on EVAP VSV and that resistance is within specification. See EVAP VACUUM SWITCHING VALVE RESISTANCE table. Replace EVAP VSV if no continuity exists or resistance is not within specification. EVAP VACUUM SWITCHING VALVE RESISTANCE Application Ohms @ 68F (20C) Camry & Camry Solara 30-34 Celica, Corolla, ECHO, MR2 27-33 & Prius Highlander, RAV4 & Tacoma 30-34 3. Using ohmmeter, ensure no continuity exists between each electrical terminal and body of EVAP VSV. Replace EVAP VSV if continuity exists between electrical terminal and body of EVAP VSV. 4. To test EVAP VSV operation, apply air pressure to port "E". Ensure air does not flow from port "F". Perform STEP 1 in illustration. See Fig. 207 -Fig. 211 . 5. Apply battery voltage and ground to electrical terminals on EVAP VSV. Apply air pressure to port "E". Ensure air flows from port "F". Perform STEP 2 in illustration. See Fig. 207 -Fig. 211 . Replace EVAP VSV if defective.

2002 ENGINE PERFORMANCE System & Component Testing - 4-Cylinder

Fig. 208: Testing Typical EVAP Vacuum Switching Valve (Celica &Corolla) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 ENGINE PERFORMANCE System & Component Testing - 4-Cylinder

for testing airtightness of fuel tank and components along with testing of charcoal canister, overfill check valve and fuel EVAP system. See appropriate FUEL EVAP SYSTEM TEST.
Pressure Switching Valve Vacuum Switching Valve (Camry, Camry Solara, Celica, Corolla, Highlander, MR2, RAV4 & Tacoma)

1. Remove pressure switching valve Vacuum Switching Valve (VSV). See PRESSURE SWITCHING VALVE VACUUM SWITCHING VALVE LOCATION table. See Fig. 160 -Fig. 166 . PRESSURE SWITCHING VALVE VACUUM SWITCHING VALVE LOCATION Application Location Camry On Bracket At Charcoal Canister Near Fuel Tank & Contains Blue 2-Pin Electrical Connector With Violet & Black/Red Wires Camry Solara On Bracket At Charcoal Canister Near Fuel Tank & Contains Blue 2-Pin Electrical Connector With White/Red & Red Wires Celica On Bracket At Charcoal Canister Near Fuel Tank & Contains Blue 2-Pin Electrical Connector With Green/Orange & Black/White Wires Corolla On Bracket At Charcoal Canister Near Fuel Tank & Contains Black 2-Pin Electrical Connector With Red & Black Wires Highlander On Bracket At Charcoal Canister Near Fuel Tank & Contains Blue 2-Pin Electrical Connector With White & Green/Yellow Wires MR2 Below Driver's Side Luggage Compartment, On Bracket At Charcoal Canister Near Fuel Tank & Contains Blue 2-Pin Electrical Connector With Blue/White & Black/Red Wires RAV4 On Bracket At Charcoal Canister Near Fuel Tank & Contains Blue 2-Pin Electrical Connector With Green/Orange & Black/Red Wires Tacoma On Bracket At Charcoal Canister Near Fuel Tank & Contains Blue 2-Pin Electrical Connector With Green/Black & White/Red Wires 2. Using ohmmeter, ensure continuity exists between electrical terminals on pressure switching valve VSV and that resistance is within specification. See PRESSURE SWITCHING VALVE VACUUM SWITCHING VALVE RESISTANCE table. Replace pressure switching valve VSV if no continuity exists or resistance is not within specification.

2002 ENGINE PERFORMANCE System & Component Testing - 4-Cylinder

PRESSURE SWITCHING VALVE VACUUM SWITCHING VALVE RESISTANCE Application Ohms @ 68F (20C) Camry 30-36 (1) Camry Solara & Celica Corolla 37-44 Highlander, MR2, RAV4 & 30-36 Tacoma (1) Resistance should be 37-44 ohms at 68F (20C) and 5162 ohms at 248 F (120C). 3. Ensure no continuity exists between each electrical terminal and body of pressure switching valve VSV. Replace pressure switching valve VSV if continuity exists between electrical terminal and body of pressure switching valve VSV. 4. To test pressure switching valve VSV operation, apply air pressure to port "E". Ensure air does not flow from port "F". Perform STEP 1 in illustration. See Fig. 212 -Fig. 214 . 5. Apply battery voltage and ground to electrical terminals on pressure switching valve VSV. Apply air pressure to port "E". Ensure air flows from port "F". Perform STEP 2 in illustration. See Fig. 212 Fig. 214 . Replace pressure switching valve VSV if defective.

2002 ENGINE PERFORMANCE System & Component Testing - 4-Cylinder

Fig. 213: Testing Pressure Switching Valve Vacuum Switching Valve (Corolla) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 ENGINE PERFORMANCE System & Component Testing - 4-Cylinder

WARNING: Read service precautions before proceeding with service procedure. See SERVICE PRECAUTIONS . 1. Remove purge flow switching valve Vacuum Switching Valve (VSV). Purge flow switching valve VSV is located on bracket at charcoal canister on top of fuel tank and contains Blue 2-pin electrical connector with Black and Black/Red wires. See Fig. 165 . If necessary to remove fuel tank for access to purge flow switching valve VSV, see FUEL PUMP under FUEL SYSTEMS in REMOVAL, OVERHAUL & INSTALLATION - 4-CYLINDER article for removal of fuel tank. 2. Using ohmmeter, ensure continuity exists between electrical terminals on purge flow switching valve VSV and that resistance is 33-39 ohms at 68F (20C). Replace purge flow switching valve VSV if no continuity exists or resistance is not within specification. 3. Ensure no continuity exists between each electrical terminal and body of purge flow switching valve VSV. Replace purge flow switching valve VSV if continuity exists between electrical terminal and body of purge flow switching valve VSV. 4. To test purge flow switching valve VSV operation, apply air pressure to port "E". Ensure air flows from port "F" and not from port "G". Perform STEP 1 in illustration. See Fig. 215 . 5. Apply battery voltage and ground to electrical terminals on purge flow switching valve VSV. Apply air pressure to port "G". Ensure air flows from port "F" and not from port "E". Perform STEP 2 in illustration. See Fig. 215 . Replace purge flow switching valve VSV if defective.

2002 ENGINE PERFORMANCE System & Component Testing - 4-Cylinder

Vapor Pressure Sensor (Camry Solara, Corolla, MR2 & RAV4)

1. Ensure ignition is off. To test vapor pressure sensor supply voltage, disconnect electrical connector from vapor pressure sensor. See VAPOR PRESSURE SENSOR LOCATION table. See Fig. 160 , Fig. 162 , Fig. 164 and Fig. 166 . For additional information for obtaining access to vapor pressure sensor, see VAPOR PRESSURE SENSOR under EMISSION SYSTEMS & SUB-SYSTEMS in REMOVAL, OVERHAUL & INSTALLATION - 4-CYLINDER article. VAPOR PRESSURE SENSOR LOCATION Application Location Camry Solara On Charcoal Canister Near Fuel Tank & Contains Black 3-Pin Electrical Connector With Blue/Red, Brown & Yellow Wires Corolla On Charcoal Canister Near Fuel Tank & Contains Black 3-Pin Electrical Connector With Brown, Blue & Yellow Wires MR2 On Top Of Fuel Pump Assembly On Fuel Tank, Below Cover Plate & Luggage Compartment Boxes Behind Seats & Contains Black 3-Pin Electrical Connector With Brown, Blue/Red & Green/Black Wires RAV4 On Top Of Fuel Pump Assembly On Fuel Tank, Below Cover Plate & Driver's Side Rear Seat & Contains Black 3-Pin Electrical Connector With Brown, Yellow & Blue/Black Wires 2. Turn ignition on. Using voltmeter, measure vapor pressure sensor supply voltage between terminals VC and E2 on wiring harness side of electrical connector for vapor pressure sensor. See Fig. 216 and Fig. 217 . VC and E2 terminals are the 2 outer terminals. DO NOT use center terminal. Vapor pressure sensor supply voltage should be 4.5-5.5 volts.

2002 ENGINE PERFORMANCE System & Component Testing - 4-Cylinder

Fig. 216: Measuring Typical Vapor Pressure Sensor Supply Voltage (Camry Solara & Corolla) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 ENGINE PERFORMANCE System & Component Testing - 4-Cylinder

Fig. 217: Measuring Vapor Pressure Sensor Supply Voltage & Identifying Air Passage On Vapor Pressure Sensor (MR2 & RAV4) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 3. If vapor pressure sensor supply voltage is within specification, turn ignition off. Reinstall electrical connector on vapor pressure sensor. Go to next step. If vapor pressure sensor supply voltage is not within specification, check wiring circuit between Engine Control Module (ECM) and vapor pressure sensor. See WIRING DIAGRAMS article. See ENGINE CONTROL MODULE LOCATION table. 4. On Camry Solara and Corolla, to test vapor pressure sensor output voltage, turn ignition on. Disconnect proper vacuum hose from vapor pressure sensor. See Fig. 218 and Fig. 219 . On MR2 and RAV4, to test vapor pressure sensor output voltage, turn ignition on. Remove retaining clip and remove vapor pressure sensor from top of fuel pump assembly. On all models, obtain access to Engine Control Module (ECM). See ENGINE CONTROL MODULE LOCATION table. ENGINE CONTROL MODULE LOCATION Model Camry Solara Corolla
(1) Location

Behind Glove Box Behind Stereo On Instrument Panel, Just In Front Of Center Console MR2 On Inside Of Firewall, Directly Behind Driver's Seat & Luggage Compartment RAV4 Near Passenger's Side Kick Panel, Just Below Instrument Panel (1) For illustration of ECM location, see THEORY & OPERATION article. For information on accessing ECM, see ENGINE CONTROL MODULE under COMPUTERIZED ENGINE CONTROLS in REMOVAL, OVERHAUL & INSTALLATION - 4CYLINDER article.

2002 ENGINE PERFORMANCE System & Component Testing - 4-Cylinder

Fig. 218: Disconnecting Vacuum Hose At Vapor Pressure Sensor (Camry Solara) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 219: Disconnecting Vacuum Hose At Vapor Pressure Sensor (Corolla) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 ENGINE PERFORMANCE System & Component Testing - 4-Cylinder

5. Connect voltmeter between specified ECM terminals. See Fig. 220 -Fig. 223 . See ECM TERMINAL APPLICATION table. ECM TERMINAL APPLICATION Application & Terminal Wire Color Camry Solara E2 Brown PTNK Blue/Red Corolla E2 Brown PTNK Blue MR2 E2 Brown PTNK Green/Black RAV4 E2 Brown (1) Blue/Black Or White PTNK
(1) There are 2 different wiring harnesses

used. Wire color at designated terminal may vary according to wiring harness used. 6. Ensure ignition is on and electrical connector is installed on vapor pressure sensor. On Camry Solara and Corolla, using vacuum pump, apply .59 in. Hg of vacuum to disconnected vacuum hose port on vapor pressure sensor and note vapor pressure sensor output voltage. On MR2 and RAV4, using vacuum pump, apply .59 in. Hg of vacuum to air passage on vapor pressure sensor and note vapor pressure sensor output voltage. SeeFig. 217 . On all models, ensure vapor pressure sensor output voltage is within specification. See VAPOR PRESSURE SENSOR OUTPUT VOLTAGE table. 7. Release vacuum from vapor pressure sensor and note vapor pressure sensor output voltage. Ensure vapor pressure sensor output voltage is within specification. See VAPOR PRESSURE SENSOR OUTPUT VOLTAGE table. 8. Apply .22 psi (.015 kg/cm2 ) of pressure to vapor pressure sensor and note vapor pressure sensor output voltage. Ensure vapor pressure sensor output voltage is within specification. See VAPOR PRESSURE SENSOR OUTPUT VOLTAGE table. Replace vapor pressure sensor if vapor pressure sensor output voltage is not within specification. Turn ignition off. VAPOR PRESSURE SENSOR OUTPUT VOLTAGE Condition Vacuum Applied Vacuum Released Pressure Applied

Volts 1.3-2.1 3.0-3.6 4.2-4.8

2002 ENGINE PERFORMANCE System & Component Testing - 4-Cylinder

Fig. 221: Measuring Vapor Pressure Sensor Output Voltage (Corolla) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 ENGINE PERFORMANCE System & Component Testing - 4-Cylinder

1. Ensure ignition is off. To test vapor pressure sensor supply voltage, remove rear seat cushion and cover plate for access to electrical connector at vapor pressure sensor. On Celica, vapor pressure sensor is located on top of fuel pump assembly on top of fuel tank and contains Black 3-pin electrical connector with Brown, Red and Blue/Black wires. See Fig. 224 . On ECHO, vapor pressure sensor is located on top of fuel pump assembly on top of fuel tank and contains Black 3-pin electrical connector with Brown, Red/White and Black wires. See Fig. 224 . 2. On all models, disconnect electrical connector from vapor pressure sensor. Turn ignition on. Using voltmeter, measure vapor pressure sensor supply voltage between terminals No. 1 and 3 on wiring harness side of electrical connector for vapor pressure sensor. See Fig. 224 . DO NOT use center terminal. Vapor pressure sensor supply voltage should be 4.5-5.5 volts. 3. If vapor pressure sensor supply voltage is within specification, turn ignition off. Reinstall electrical connector on vapor pressure sensor. Go to next step. If vapor pressure sensor supply voltage is not within specification, check wiring circuit between Engine Control Module (ECM) and vapor pressure sensor. See WIRING DIAGRAMS article. On Celica, ECM is located in engine compartment, below cover, just in front of battery, next to driver's side strut tower. On ECHO, ECM is located behind glove box. On all models, for illustration of ECM location, see THEORY & OPERATION article. For information on accessing ECM, see ENGINE CONTROL MODULE under COMPUTERIZED ENGINE CONTROLS in REMOVAL, OVERHAUL & INSTALLATION - 4-CYLINDER article. 4. To test vapor pressure sensor output voltage, ensure electrical connector is installed on vapor pressure sensor. Turn ignition on. Remove fuel tank cap. Using voltmeter, measure vapor pressure sensor output voltage between terminals No. 2 and 3 on wiring harness side of electrical connector for vapor pressure sensor with electrical connector installed on vapor pressure sensor. See Fig. 224 . 5. Vapor pressure sensor output voltage should be 3.0-3.6 volts. Replace vapor pressure sensor if vapor pressure sensor output voltage is not within specification. Turn ignition off. Reinstall fuel tank cap, cover plate and rear seat cushion.

2002 ENGINE PERFORMANCE System & Component Testing - 4-Cylinder

Vapor Pressure Sensor (Prius)

WARNING: Read service precautions before proceeding with service procedure. See SERVICE PRECAUTIONS . 1. Ensure ignition is off. To test vapor pressure sensor supply voltage, disconnect electrical connector at vapor pressure sensor. Vapor pressure sensor is located on top of fuel tank and contains Black 3-pin electrical connector with Brown, Blue/Red and Yellow/Red wires. See Fig. 225 . It may be necessary to lower fuel tank for access to electrical connector at vapor pressure sensor. 2. Disconnect electrical connector from vapor pressure sensor. Turn ignition on. Using voltmeter, measure vapor pressure sensor supply voltage between terminals No. 1 and 3 on wiring harness side of electrical connector for vapor pressure sensor. See Fig. 225 . DO NOT use center terminal. Vapor pressure sensor supply voltage should be 4.5-5.5 volts. 3. If vapor pressure sensor supply voltage is within specification, turn ignition off. Reinstall electrical connector on vapor pressure sensor. Go to next step. If vapor pressure sensor supply voltage is not within specification, check wiring circuit between Engine Control Module (ECM) and vapor pressure sensor. See WIRING DIAGRAMS article. ECM is located behind glove box. For illustration of ECM location, see THEORY & OPERATION article. 4. To test vapor pressure sensor output voltage, ensure electrical connector is installed on vapor pressure sensor. Turn ignition on. Remove fuel tank cap. Using voltmeter, measure vapor pressure sensor output voltage between terminals No. 2 and 3 on wiring harness side of electrical connector for vapor pressure sensor with electrical connector installed on vapor pressure sensor. See Fig. 225 . 5. Vapor pressure sensor output voltage should be 3.0-3.6 volts. Replace vapor pressure sensor if vapor pressure sensor output voltage is not within specification. Turn ignition off. Reinstall fuel tank cap.

2002 ENGINE PERFORMANCE System & Component Testing - 4-Cylinder

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Vapor Pressure Sensor (Tacoma)

1. Ensure ignition is off. To test vapor pressure sensor supply voltage, disconnect electrical connector from vapor pressure sensor. Vapor pressure sensor is located on top of fuel pump assembly on top of fuel tank and contains Black 3-pin electrical connector with Green/Yellow, Red/Yellow and Blue/Black wires. See Fig. 226 . 2. Turn ignition on. Using voltmeter, measure vapor pressure sensor supply voltage between terminals VC and E2 on wiring harness side of electrical connector for vapor pressure sensor. See Fig. 226 . DO NOT use center terminal. Vapor pressure sensor supply voltage should be 4.5-5.5 volts. 3. If vapor pressure sensor supply voltage is within specification, turn ignition off. Reinstall electrical connector on vapor pressure sensor. Go to next step. If vapor pressure sensor supply voltage is not within specification, check wiring circuit between Engine Control Module (ECM) and vapor pressure sensor. See WIRING DIAGRAMS article. ECM is located behind the glove box. For illustration of ECM location, see THEORY & OPERATION article. For information on accessing ECM, see ENGINE CONTROL MODULE under COMPUTERIZED ENGINE CONTROLS in REMOVAL, OVERHAUL & INSTALLATION - 4-CYLINDER article. 4. To test vapor pressure sensor output voltage, turn ignition on. Ensure electrical connector is installed on vapor pressure sensor. Remove fuel tank cap. Using voltmeter, check voltage between ECM terminals E2 (Brown wire) and PTNK (Red/Yellow wire). See Fig. 227 . Vapor pressure sensor output voltage should be 3.0-3.6 volts. Replace vapor pressure sensor if vapor pressure sensor output voltage is not within specification. Turn ignition off. Reinstall fuel tank cap.

Fig. 226: Locating Vapor Pressure Sensor & Measuring Vapor Pressure Sensor Supply Voltage (Tacoma) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 ENGINE PERFORMANCE System & Component Testing - 4-Cylinder

Fig. 227: Measuring Vapor Pressure Sensor Output Voltage (Tacoma) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. POSITIVE CRANKCASE VENTILATION
Camry & Highlander

1. Remove Positive Crankcase Ventilation (PCV) valve. PCV valve is located at passenger's side front corner of valve cover, just above intake manifold. Apply air pressure to PCV valve at bottom (cylinder head side) of PCV valve. Ensure air flows easily through PCV valve. 2. Apply air pressure to PCV valve at vacuum side (intake manifold side) of PCV valve. Ensure air flows through PCV valve with some resistance. Replace PCV valve if valve does not function as described.
Camry Solara, Celica, Corolla, ECHO, MR2, Prius, RAV4 & Tacoma

WARNING: On Prius, read service precautions before proceeding with service procedure. See SERVICE PRECAUTIONS . 1. Remove Positive Crankcase Ventilation (PCV) valve. See Fig. 160 -Fig. 167 . Apply air pressure to PCV valve at bottom (cylinder head side) of PCV valve. Ensure air flows easily through PCV valve. 2. Apply air pressure to PCV valve at vacuum side (intake manifold side) of PCV valve. Ensure air flows through PCV valve with some resistance. Replace PCV valve if valve does not function as described.

THROTTLE CONTROLS

2002 ENGINE PERFORMANCE System & Component Testing - 4-Cylinder

ELECTRONIC THROTTLE CONTROL SYSTEM NOTE: Electronic Throttle Control System (ETCS) may also be referred to as Electronic Throttle Control System-Intelligent (ETCS-I or ETCS-i).

Camry, Camry Solara, MR2 With Sequential Manual Transaxle & Prius

For testing of throttle body and components, see THROTTLE BODY under IDLE CONTROL SYSTEMS. THROTTLE OPENER
Tacoma

1. Start engine and warm engine to normal operating temperature. Ensure idle speed is within specification. See IDLE SPEED & MIXTURE in ON-VEHICLE ADJUSTMENTS - 4-CYLINDER article. 2. With engine idling, disconnect and plug vacuum hose at throttle opener. See Fig. 228 . Note engine speed with vacuum hose disconnected from throttle opener. Engine speed should be 1200-1500 RPM. 3. Throttle opener is nonadjustable. If engine speed is not within specification, replace throttle body. See THROTTLE BODY under FUEL SYSTEMS in REMOVAL, OVERHAUL & INSTALLATION 4-CYLINDER article. Shut engine off. Reinstall vacuum hose on throttle opener. Start engine and ensure engine returns to proper idle speed.

Fig. 228: Locating Throttle Opener & Disconnecting Vacuum Hose (Tacoma) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

VARIABLE VALVE LIFT SYSTEM

2002 ENGINE PERFORMANCE System & Component Testing - 4-Cylinder

NOTE:

Variable Valve Lift (VVL) system may also be referred to as Variable Valve Timing Lift Intelligent (VVTL-I or VVTL-i) system. VVL system is used only on Celica 1.8L 2ZZ-GE. If problem exists in VVL system, a Diagnostic Trouble Code (DTC) may be stored in Engine Control Module (ECM). See TESTING PROCEDURE under SELF-DIAGNOSTIC SYSTEM in appropriate SELF-DIAGNOSTICS article for retrieving of DTCs.

NOTE:

VARIABLE VALVE LIFT OIL CONTROL VALVE NOTE: Variable Valve Lift (VVL) oil control valve may also be referred to as VVL Oil Control Valve (OCV) or camshaft timing oil control valve (VVL).

Celica 1.8L 2ZZ-GE

1. Remove No. 2 cylinder head cover located on top of engine, above ignition coils and valve cover. To check VVL oil control valve resistance, disconnect electrical connector at VVL oil control valve. VVL oil control valve is located at intake manifold side of cylinder head, near flywheel end of engine. See Fig. 229 . 2. Using ohmmeter, check resistance between electrical terminals on VVL oil control valve. Resistance should be 6.9-7.9 ohms at 68F (20C). If resistance is within specification, go to next step. If resistance is not within specification, replace VVL oil control valve. See VARIABLE VALVE LIFT OIL CONTROL VALVE under VARIABLE VALVE LIFT SYSTEM in REMOVAL, OVERHAUL & INSTALLATION - 4-CYLINDER article. 3. To check VVL oil control valve operation, remove VVL oil control valve. See VARIABLE VALVE LIFT OIL CONTROL VALVE under VARIABLE VALVE LIFT SYSTEM in REMOVAL, OVERHAUL & INSTALLATION - 4-CYLINDER article. 4. Note movement of valve inside VVL oil control valve while applying and disconnecting battery voltage and ground to terminals No. 1 and 2 on VVL oil control valve. See Fig. 235 . Valve should move outward toward end of assembly opposite electrical connector with voltage applied and should move inward toward electrical connector end of assembly with voltage not applied. See Fig. 235 . Replace VVL oil control valve if operation is not as specified.

VARIABLE VALVE TIMING SYSTEM

NOTE: Variable Valve Timing (VVT) system is used on Camry, Camry Solara, Celica, Corolla, ECHO, Highlander, MR2, Prius & RAV4. If problem exists in VVT system, a Diagnostic Trouble Code (DTC) may be stored in Engine Control Module (ECM). See TESTING PROCEDURE under SELF-DIAGNOSTIC SYSTEM in appropriate SELF-DIAGNOSTICS article for retrieving of DTCs.

VARIABLE VALVE TIMING SENSOR

Camry, Camry Solara, Celica, Corolla, ECHO, Highlander, MR2, Prius & RAV4

NOTE:

Variable Valve Timing (VVT) sensor may also be referred to as camshaft position sensor.

2002 ENGINE PERFORMANCE System & Component Testing - 4-Cylinder

For VVT sensor testing, see CAMSHAFT POSITION SENSOR under IGNITION SYSTEMS in BASIC DIAGNOSTIC PROCEDURES - 4-CYLINDER article. VARIABLE VALVE TIMING CAMSHAFT TIMING OIL CONTROL VALVE
Camry, Camry Solara, Celica, Corolla, ECHO, Highlander, MR2, Prius & RAV4

NOTE:

Variable Valve Timing (VVT) camshaft timing oil control valve may also be referred to as oil control valve for VVT, VVT Oil Control Valve (OCV) or camshaft timing oil control valve VVT. WARNING: On Prius, read service precautions before proceeding with service procedure. See SERVICE PRECAUTIONS .

1. Remove No. 2 cylinder head cover located on top of engine, above ignition coils and valve cover (if necessary) for access to VVT camshaft timing oil control valve. VVT camshaft timing oil control valve is located at intake manifold side of cylinder head, near timing chain end of engine. See Fig. 229 -Fig. 234 . . To check VVT camshaft timing oil control valve resistance, disconnect electrical connector at VVT camshaft timing oil control valve. 2. Using ohmmeter, check resistance between electrical terminals on VVT camshaft timing oil control valve. Ensure resistance is within specification. See VVT CAMSHAFT TIMING OIL CONTROL VALVE RESISTANCE table. If resistance is within specification, go to next step. If resistance is not within specification, replace VVT camshaft timing oil control valve. See VARIABLE VALVE TIMING CAMSHAFT TIMING OIL CONTROL VALVE under VARIABLE VALVE TIMING SYSTEM in REMOVAL, OVERHAUL & INSTALLATION - 4-CYLINDER article. VVT CAMSHAFT TIMING OIL CONTROL VALVE RESISTANCE Application Ohms @ 68F (20C) Camry, Camry Solara, Celica, 6.9-7.9 Corolla, Highlander, MR2, Prius & RAV4 ECHO 5.5-12.0 3. To check VVT camshaft timing oil control valve operation, remove VVT camshaft timing oil control valve. See VARIABLE VALVE TIMING CAMSHAFT TIMING OIL CONTROL VALVE under VARIABLE VALVE TIMING SYSTEM in REMOVAL, OVERHAUL & INSTALLATION 4-CYLINDER article. 4. Note movement of valve inside VVT camshaft timing oil control valve while applying and disconnecting battery voltage and ground to terminals No. 1 and 2 on VVT camshaft timing oil control valve. See Fig. 235 and Fig. 236 . Valve should move outward toward end of assembly opposite electrical connector with voltage applied, and should move inward toward electrical connector end of assembly with voltage not applied. See Fig. 235 and Fig. 236 . Replace VVT camshaft timing oil control valve if operation is not as specified.

2002 ENGINE PERFORMANCE System & Component Testing - 4-Cylinder

Fig. 232: Locating Variable Valve Timing Camshaft Timing Oil Control Valve (Corolla) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 ENGINE PERFORMANCE System & Component Testing - 4-Cylinder

Fig. 235: Testing Typical Oil Control Valve Operation (Camry, Camry Solara, Celica, Corolla, Highlander, MR2, Prius & RAV4) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 ENGINE PERFORMANCE Trouble Shooting - No Codes

2002 ENGINE PERFORMANCE Trouble Shooting - No Codes

INTRODUCTION
NOTE: Before using Trouble Shooting - No Codes article, check for any related Technical Service Bulletins (TSBs) that may apply.

Before diagnosing symptoms or intermittent faults, follow proper workflow. See TESTING PROCEDURE under SELF-DIAGNOSTIC SYSTEM in appropriate SELF-DIAGNOSTICS article. If no Diagnostic Trouble Codes (DTC) are present and a no start condition exists, proceed to appropriate BASIC DIAGNOSTIC PROCEDURES article. If no DTCs are present and a driveability condition exists, diagnosis by symptom (i.e., ROUGH IDLE, ENGINE STALLS, etc.). NOTE: Some driveability problems may have been corrected by manufacturer with a revised Engine Control Module (ECM). Check with manufacturer for latest ECM application.

Symptom checks can direct the technician to malfunctioning component(s) for further diagnosis. A symptom should lead to a specific component, system test or adjustment. Use intermittent test procedures to locate driveability problems that do not occur when the vehicle is being tested. These test procedures should also be used if an intermittent diagnostic trouble code was present, but no problem was found during self-diagnostic testing.

SYMPTOMS
SYMPTOM DIAGNOSIS CAUTION: When battery is disconnected, vehicle computer may lose memory data. Driveability problems may exist until computer systems have completed a relearn cycle. Symptom checks cannot be used properly unless the problem occurs while the vehicle is being tested. To reduce diagnostic time, ensure steps in appropriate BASIC DIAGNOSTIC PROCEDURES and appropriate SELF-DIAGNOSTICS articles were performed before diagnosing a symptom. Following symptoms are available for diagnosis.

Does Not Start Difficult To Start Poor Idling Poor Driveability Engine Stalls Refueling Problem A/C Switch Indicator Blinking

2002 ENGINE PERFORMANCE Trouble Shooting - No Codes

DOES NOT START Engine Does Not Crank

On all models except Prius, check battery and battery cables. On all models except Prius, check starter. See appropriate STARTERS article in STARTING & CHARGING SYSTEMS. On all models except Prius, check starter relay. See appropriate STARTERS article in STARTING & CHARGING SYSTEMS. On A/T models except MR2 and Prius, check park/neutral position switch. See PARK/NEUTRAL POSITION SWITCH under ENGINE SENSORS & SWITCHES in appropriate SYSTEM & COMPONENT TESTING article. On Prius, the Hybrid Vehicle (HV) control Electronic Control Unit (ECU) or Motor Generator No. 1 (MG1) may be the problem. Consult authorized dealer for servicing.

No Initial Combustion

Check Engine Control Module (ECM) power source circuit. See ENGINE CONTROL MODULE POWER SOURCE CIRCUIT under COMPUTERIZED ENGINE CONTROLS in appropriate SYSTEM & COMPONENT TESTING article. On Avalon, Camry 2.2L 4-cylinder gasoline models, Camry 3.0L V6, Camry Solara, Highlander, Land Cruiser, MR2, Prius, RAV4, Sequoia, Sienna and 4Runner, check engine immobilizer system (if equipped). See appropriate ENGINE IMMOBILIZER SYSTEMS article in ACCESSORIES & EQUIPMENT. On Avalon, Camry 2.2L 4-cylinder gasoline models, Camry 3.0L V6, Camry Solara, Celica, Corolla, ECHO, Highlander, MR2, Prius, RAV4, Sienna, Tacoma, Tundra 3.4L V6 and 4Runner, check fuel pump control circuit. See FUEL PUMP CONTROL CIRCUIT under COMPUTERIZED ENGINE CONTROLS in appropriate SYSTEM & COMPONENT TESTING article. On Land Cruiser, check fuel pump control circuit. See DTC P1200: FUEL PUMP RELAY/ECU CIRCUIT test in SELF-DIAGNOSTICS - LAND CRUISER article. Also, check fuel pump switch. See FUEL PUMP SWITCH (LAND CRUISER) under FUEL DELIVERY under FUEL SYSTEM in SYSTEM & COMPONENT TESTING - V6 & V8 article. On Sequoia and Tundra 4.7L V8, check fuel pump control circuit. See DTC P1200: FUEL PUMP RELAY CIRCUIT test in appropriate SELF-DIAGNOSTICS article. On all models, check Engine Control Module (ECM) electrical connector for loose, damaged or corroded terminals and repair as necessary. For illustration of ECM location, see THEORY & OPERATION article. If electrical connector is okay, check ECM ground circuits. See WIRING DIAGRAMS article. Repair as necessary. If ground circuits are okay, replace ECM with a knowngood ECM and retest.

No Complete Combustion

On Avalon, Camry 2.2L 4-cylinder gasoline models, Camry 3.0L V6, Camry Solara, Celica, Corolla, ECHO, Highlander, MR2, Prius, RAV4, Sienna, Tacoma, Tundra 3.4L V6 and 4Runner, check fuel pump control circuit. See FUEL PUMP CONTROL CIRCUIT under COMPUTERIZED ENGINE CONTROLS in appropriate SYSTEM & COMPONENT TESTING article. On Land Cruiser, check fuel pump control circuit. See DTC P1200: FUEL PUMP RELAY/ECU CIRCUIT test in SELF-DIAGNOSTICS - LAND CRUISER article.

2002 ENGINE PERFORMANCE Trouble Shooting - No Codes

On Sequoia and Tundra 4.7L V8, check fuel pump control circuit. See DTC P1200: FUEL PUMP RELAY CIRCUIT test in appropriate SELF-DIAGNOSTICS article.

DIFFICULT TO START Difficult To Start & Engine Cranks Normally

On Avalon, Camry, Camry Solara, Corolla, Highlander, Land Cruiser, MR2, RAV4, Sequoia, Sienna, Tacoma, Tundra and 4Runner, check starter signal circuit. See STARTER SIGNAL CIRCUIT under COMPUTERIZED ENGINE CONTROLS in appropriate SYSTEM & COMPONENT TESTING article. On Celica and ECHO, check starter signal circuit at STA terminal on Engine Control Module (ECM). See WIRING DIAGRAMS article. For illustration of ECM location, see THEORY & OPERATION article. No other testing information is available from manufacturer. On Avalon, Camry 2.2L 4-cylinder gasoline models, Camry 3.0L V6, Camry Solara, Celica, Corolla, ECHO, Highlander, MR2, Prius, RAV4, Sienna, Tacoma, Tundra 3.4L V6 and 4Runner, check fuel pump control circuit. See FUEL PUMP CONTROL CIRCUIT under COMPUTERIZED ENGINE CONTROLS in appropriate SYSTEM & COMPONENT TESTING article. On Land Cruiser, check fuel pump control circuit. See DTC P1200: FUEL PUMP RELAY/ECU CIRCUIT test in SELF-DIAGNOSTICS - LAND CRUISER article. On with sequential manual transaxle, check throttle body and components for Electronic Throttle Control System (ETCS). See THROTTLE BODY under IDLE CONTROL SYSTEMS in SYSTEM & COMPONENT TESTING - 4-CYLINDER article. Models with sequential manual transaxle may be identified by the shift lever pattern which consists of "R", "N", "S" and "+" in place of the conventional type shift lever pattern and no clutch pedal is used. On Sequoia and Tundra 4.7L V8, check fuel pump control circuit. See DTC P1200: FUEL PUMP RELAY CIRCUIT test in appropriate SELF-DIAGNOSTICS article. On all models, check engine compression. See MECHANICAL INSPECTION under PRELIMINARY INSPECTION & ADJUSTMENTS in appropriate BASIC DIAGNOSTIC PROCEDURES article.

Difficult To Start When Engine Is Hot Or Cold

On Avalon, Camry, Camry Solara, Corolla, Highlander, Land Cruiser, MR2, RAV4, Sequoia, Sienna, Tacoma, Tundra and 4Runner, check starter signal circuit. See STARTER SIGNAL CIRCUIT under COMPUTERIZED ENGINE CONTROLS in appropriate SYSTEM & COMPONENT TESTING article. On Celica and ECHO, check starter signal circuit at STA terminal on Engine Control Module (ECM). See WIRING DIAGRAMS article. For illustration of ECM location, see THEORY & OPERATION article. No other testing information is available from manufacturer. On Avalon, Camry 2.2L 4-cylinder gasoline models, Camry 3.0L V6, Camry Solara, Celica, Corolla, ECHO, Highlander, MR2, Prius, RAV4, Sienna, Tacoma, Tundra 3.4L V6 and 4Runner, check fuel pump control circuit. See FUEL PUMP CONTROL CIRCUIT under COMPUTERIZED ENGINE CONTROLS in appropriate SYSTEM & COMPONENT TESTING article. On Land Cruiser, check fuel pump control circuit. See DTC P1200: FUEL PUMP RELAY/ECU CIRCUIT test in SELF-DIAGNOSTICS - LAND CRUISER article. On MR2 with sequential manual transaxle, check throttle body and components for Electronic Throttle Control System (ETCS). See THROTTLE BODY under IDLE CONTROL SYSTEMS in

2002 ENGINE PERFORMANCE Trouble Shooting - No Codes

SYSTEM & COMPONENT TESTING - 4-CYLINDER article. Models with sequential manual transaxle may be identified by the shift lever pattern which consists of "R", "N", "S" and "+" in place of the conventional type shift lever pattern and no clutch pedal is used. On Sequoia and Tundra 4.7L V8, check fuel pump control circuit. See DTC P1200: FUEL PUMP RELAY CIRCUIT test in appropriate SELF-DIAGNOSTICS article.

POOR IDLING High Idle Speed

Check A/C signal. A/C signal may also be referred to as A/C switch signal or compressor circuit. See appropriate MANUAL or AUTOMATIC A/C-HEATER SYSTEMS article in AIR CONDITIONING & HEATING. On MR2 with sequential manual transaxle, check throttle body and components for Electronic Throttle Control System (ETCS). See THROTTLE BODY under IDLE CONTROL SYSTEMS in SYSTEM & COMPONENT TESTING - 4-CYLINDER article. Models with sequential manual transaxle may be identified by the shift lever pattern which consists of "R", "N", "S" and "+" in place of the conventional type shift lever pattern and no clutch pedal is used. On all models, check Engine Control Module (ECM) power source circuit. See ENGINE CONTROL MODULE POWER SOURCE CIRCUIT under COMPUTERIZED ENGINE CONTROLS in appropriate SYSTEM & COMPONENT TESTING article.

Low Idle Speed

Check A/C signal. A/C signal may also be referred to as A/C switch signal or compressor circuit. See appropriate MANUAL or AUTOMATIC A/C-HEATER SYSTEMS article in AIR CONDITIONING & HEATING. On Avalon, Camry 2.2L 4-cylinder gasoline models, Camry 3.0L V6, Camry Solara, Celica, Corolla, ECHO, Highlander, MR2, Prius, RAV4, Sienna, Tacoma, Tundra 3.4L V6 and 4Runner, check fuel pump control circuit. See FUEL PUMP CONTROL CIRCUIT under COMPUTERIZED ENGINE CONTROLS in appropriate SYSTEM & COMPONENT TESTING article. On Land Cruiser, check fuel pump control circuit. See DTC P1200: FUEL PUMP RELAY/ECU CIRCUIT test in SELF-DIAGNOSTICS - LAND CRUISER article. On MR2 with sequential manual transaxle, check throttle body and components for Electronic Throttle Control System (ETCS). See THROTTLE BODY under IDLE CONTROL SYSTEMS in SYSTEM & COMPONENT TESTING - 4-CYLINDER article. Models with sequential manual transaxle may be identified by the shift lever pattern which consists of "R", "N", "S" and "+" in place of the conventional type shift lever pattern and no clutch pedal is used. On Sequoia and Tundra 4.7L V8, check fuel pump control circuit. See DTC P1200: FUEL PUMP RELAY CIRCUIT test in appropriate SELF-DIAGNOSTICS article.

Rough Idle

Check engine compression. See MECHANICAL INSPECTION under PRELIMINARY INSPECTION & ADJUSTMENTS in appropriate BASIC DIAGNOSTIC PROCEDURES article. On Avalon, Camry 2.2L 4-cylinder gasoline models, Camry 3.0L V6, Camry Solara, Celica, Corolla, ECHO, Highlander, MR2, Prius, RAV4, Sienna, Tacoma, Tundra 3.4L V6 and 4Runner, check fuel pump control circuit. See FUEL PUMP CONTROL CIRCUIT under COMPUTERIZED ENGINE CONTROLS in appropriate SYSTEM & COMPONENT TESTING article.

2002 ENGINE PERFORMANCE Trouble Shooting - No Codes

On Land Cruiser, check fuel pump control circuit. See DTC P1200: FUEL PUMP RELAY/ECU CIRCUIT test in SELF-DIAGNOSTICS - LAND CRUISER article. On Sequoia and Tundra 4.7L V8, check fuel pump control circuit. See DTC P1200: FUEL PUMP RELAY CIRCUIT test in appropriate SELF-DIAGNOSTICS article.

Surging

Check Engine Control Module (ECM) power source circuit. See ENGINE CONTROL MODULE POWER SOURCE CIRCUIT under COMPUTERIZED ENGINE CONTROLS in appropriate SYSTEM & COMPONENT TESTING article. On Avalon, Camry 2.2L 4-cylinder gasoline models, Camry 3.0L V6, Camry Solara, Celica, Corolla, ECHO, Highlander, MR2, Prius, RAV4, Sienna, Tacoma, Tundra 3.4L V6 and 4Runner, check fuel pump control circuit. See FUEL PUMP CONTROL CIRCUIT under COMPUTERIZED ENGINE CONTROLS in appropriate SYSTEM & COMPONENT TESTING article. On Land Cruiser, check fuel pump control circuit. See DTC P1200: FUEL PUMP RELAY/ECU CIRCUIT test in SELF-DIAGNOSTICS - LAND CRUISER article. On MR2 with sequential manual transaxle, check throttle body and components for Electronic Throttle Control System (ETCS). See THROTTLE BODY under IDLE CONTROL SYSTEMS in SYSTEM & COMPONENT TESTING - 4-CYLINDER article. Models with sequential manual transaxle may be identified by the shift lever pattern which consists of "R", "N", "S" and "+" in place of the conventional type shift lever pattern and no clutch pedal is used. On Sequoia and Tundra 4.7L V8, check fuel pump control circuit. See DTC P1200: FUEL PUMP RELAY CIRCUIT test in appropriate SELF-DIAGNOSTICS article.

POOR DRIVEABILITY Hesitation/Poor Acceleration

On Avalon, Camry 2.2L 4-cylinder gasolines models, Camry 3.0L V6, Camry Solara, Celica, Corolla, ECHO, Highlander, MR2, Prius, RAV4, Sienna, Tacoma, Tundra 3.4L V6 and 4Runner, check fuel pump control circuit. See FUEL PUMP CONTROL CIRCUIT under COMPUTERIZED ENGINE CONTROLS in appropriate SYSTEM & COMPONENT TESTING article. On all models except MR2 and Prius, on models with electronic controlled automatic transaxle/transmission, check for problem with electronic controls for automatic transaxle/transmission. See appropriate ELECTRONIC CONTROLS article in AUTOMATIC TRANSMISSIONS. On Corolla, check A/C-cut control system circuit. See A/C-CUT CONTROL SYSTEM CIRCUIT under COMPUTERIZED ENGINE CONTROLS in SYSTEM & COMPONENT TESTING - 4CYLINDER article. On Land Cruiser, check fuel pump control circuit. See DTC P1200: FUEL PUMP RELAY/ECU CIRCUIT test in SELF-DIAGNOSTICS - LAND CRUISER article. On Prius, there may be a problem with the hybrid transaxle. On Sequoia and Tundra 4.7L V8, check fuel pump control circuit. See DTC P1200: FUEL PUMP RELAY CIRCUIT test in appropriate SELF-DIAGNOSTICS article.

Surging

On Avalon, Camry 2.2L 4-cylinder gasoline models, Camry 3.0L V6, Camry Solara, Celica, Corolla,

2002 ENGINE PERFORMANCE Trouble Shooting - No Codes

ECHO, Highlander, MR2, Prius, RAV4, Sienna, Tacoma, Tundra 3.4L V6 and 4Runner, check fuel pump control circuit. See FUEL PUMP CONTROL CIRCUIT under COMPUTERIZED ENGINE CONTROLS in appropriate SYSTEM & COMPONENT TESTING article. On Land Cruiser, check fuel pump control circuit. See DTC P1200: FUEL PUMP RELAY/ECU CIRCUIT test in SELF-DIAGNOSTICS - LAND CRUISER article. On Sequoia and Tundra 4.7L V8, check fuel pump control circuit. See DTC P1200: FUEL PUMP RELAY CIRCUIT test in appropriate SELF-DIAGNOSTICS article.

ENGINE STALLS Engine Starts And Then Stalls

On Avalon, Camry 2.2L 4-cylinder gasoline models, Camry 3.0L V6, Camry Solara, Celica, Corolla, ECHO, Highlander, MR2, Prius, RAV4, Sienna, Tacoma, Tundra 3.4L V6 and 4Runner, check fuel pump control circuit. See FUEL PUMP CONTROL CIRCUIT under COMPUTERIZED ENGINE CONTROLS in appropriate SYSTEM & COMPONENT TESTING article. On Land Cruiser, check fuel pump control circuit. See DTC P1200: FUEL PUMP RELAY/ECU CIRCUIT test in SELF-DIAGNOSTICS - LAND CRUISER article. On MR2 with sequential manual transaxle, check throttle body and components for Electronic Throttle Control System (ETCS). See THROTTLE BODY under IDLE CONTROL SYSTEMS in SYSTEM & COMPONENT TESTING - 4-CYLINDER article. Models with sequential manual transaxle may be identified by the shift lever pattern which consists of "R", "N", "S" and "+" in place of the conventional type shift lever pattern and no clutch pedal is used. On Sequoia and Tundra 4.7L V8, check fuel pump control circuit. See DTC P1200: FUEL PUMP RELAY CIRCUIT test in appropriate SELF-DIAGNOSTICS article.

Engine Stall During A/C Operation

Check A/C signal. A/C signal may also be referred to as A/C switch signal or compressor circuit. See appropriate MANUAL or AUTOMATIC A/C-HEATER SYSTEMS article in AIR CONDITIONING & HEATING. Check Engine Control Module (ECM) electrical connector for loose, damaged or corroded terminals and repair as necessary. For illustration of ECM location, see THEORY & OPERATION article. If electrical connector is okay, check ECM ground circuits. See WIRING DIAGRAMS article. Repair as necessary. If ground circuits are okay, replace ECM with a known-good ECM and retest.

REFUELING PROBLEM NOTE: On-Board Refilling Vapor Recovery (ORVR) system is used to recover fuel vapors into charcoal canister that are generated during refueling. Manufacturer provides procedure for only the models listed.

Unable/Difficult To Refuel

On Avalon, Camry 2.2L 4-cylinder gasoline models, Camry 3.0L V6, Camry Solara, Corolla, ECHO, Highlander and Prius, a problem may exist in the On-Board Refilling Vapor Recovery (ORVR) system. Check fuel evaporative system. See FUEL EVAP SYSTEM under EMISSION SYSTEMS & SUB-SYSTEMS in appropriate SYSTEM & COMPONENT TESTING article. Check fuel evaporative system. See FUEL EVAPORATIVE SYSTEM under EMISSION SYSTEMS

2002 ENGINE PERFORMANCE Trouble Shooting - No Codes

& SUB-SYSTEMS in appropriate SYSTEM & COMPONENT TESTING article. A/C SWITCH INDICATOR BLINKING NOTE:

Manufacturer provides procedure for only the models listed.

On Camry 2.2L 4-cylinder and Camry Solara 2.2L 4-cylinder, check A/C compressor lock sensor circuit. See A/C COMPRESSOR LOCK SENSOR CIRCUIT under COMPUTERIZED ENGINE CONTROLS in SYSTEM & COMPONENT TESTING - 4-CYLINDER article. On Camry 2.2L 4-cylinder and Camry Solara 2.2L 4-cylinder, check A/C evaporator temperature sensor circuit. See A/C EVAPORATOR TEMPERATURE SENSOR CIRCUIT under COMPUTERIZED ENGINE CONTROLS in SYSTEM & COMPONENT TESTING - 4CYLINDER article.

INTERMITTENTS
INTERMITTENT PROBLEM DIAGNOSIS Intermittent fault testing requires duplicating circuit or component failure to identify the problem. These procedures may lead to the computer setting a diagnostic trouble code (on some systems) which may help in diagnosis. If problem vehicle does not produce diagnostic trouble code codes, monitor voltage or resistance values using a DVOM while attempting to reproduce conditions causing intermittent fault. A status change on DVOM indicates a fault has been located. Use a DVOM to pinpoint faults. When monitoring voltage, ensure ignition switch is in ON position or engine is running. Ensure ignition switch is in OFF position or negative battery cable is disconnected when monitoring circuit resistance. Status changes on DVOM during test procedures indicate area of fault. TEST PROCEDURES
Intermittent Simulation

To reproduce the conditions creating an intermittent fault, use the following methods:

Lightly vibrate component. See VIBRATION METHOD . Heat component. See HEATING METHOD . Wiggle or bend wiring harness. See VIBRATION METHOD . Spray component with water. See WATER APPLICATION METHOD .

Monitor circuit/component voltage or resistance while simulating intermittent. If engine is running, monitor for diagnostic trouble codes. Use test results to identify a faulty component or circuit. VIBRATION METHOD
Wiring Harness Testing

Using DVOM, monitor suspected circuit or component. Lightly shake wiring harness while noting

2002 ENGINE PERFORMANCE Trouble Shooting - No Codes

fluctuation in DVOM reading. Inspect wiring harness at area where it goes through the body for signs of damage.
Component, Relay & Sensor Testing

Using DVOM, monitor suspected circuit or component. Lightly vibrate suspected component, relay or sensor while noting fluctuation in DVOM reading.
Electrical Connector Testing

Using DVOM, monitor suspected circuit or component. Lightly shake electrical connector while noting fluctuation in DVOM reading. Visually inspect electrical connector for damage. HEATING METHOD
Component Testing

Heat suspected component with a hair dryer while checking for a malfunction to occur. DO NOT apply heat directly to components in Engine Control Module (ECM). DO NOT heat any component to more than 140 F (60C). WATER APPLICATION METHOD CAUTION: Ensure vehicle does not have water leaks before using water application method. If water leak exists, use care when applying water that no water is sprayed directly on any electronic components. Spray outside of vehicle and front of radiator with water while checking for a malfunction to occur. DO NOT spray water directly into engine compartment. Temperature and humidity may be changed by spraying water onto front of radiator. DO NOT spray electronic components directly with water.

2002 ENGINE PERFORMANCE Theory & Operation

2002 ENGINE PERFORMANCE Theory & Operation

INTRODUCTION
WARNING: On Prius, read service precautions before proceeding with service procedure. See SERVICE PRECAUTIONS . NOTE: References to California models apply to California emission vehicles, which may be verified by underhood Emission Control label. California emissions may be available in other states.

This article covers basic description and operation of engine performance-related systems and components. Read this article before diagnosing vehicles or systems with which you are not completely familiar.

SERVICE PRECAUTIONS
PRIUS WARNING: When performing any inspection or service procedure on this vehicle, ensure following service precautions are followed to prevent personal injury or death due to the extremely high voltage. The following service precautions must be followed:

Ensure ignition is off and ignition key is removed from ignition before performing any inspection or service procedure in engine compartment, as engine may automatically start and shut off when ignition is on and READY light is illuminated. READY light is displayed just above the shift lever position indicator on instrument cluster at center of instrument panel. Read all service and warning labels in engine compartment before performing any procedures in engine compartment. All high-voltage wiring harness connectors contain Orange connectors. DO NOT touch any wiring harness that contains Orange connectors. High-voltage battery and other high-voltage components may be identified by HIGH VOLTAGE caution labels on them. DO NOT touch these components. If necessary to inspect or service high-voltage system, ensure ignition is off. Remove service plug and wait at least 5 minutes to ensure high voltage is fully discharged before touching any high-voltage wiring harness, connectors or components. Service plug is located on service plug assembly at driver's side front corner of trunk compartment, near high-voltage battery. See Fig. 1 . Ensure service plug is stored in a location in which no one may install service plug while technician is working on the vehicle. If necessary to touch any high-voltage wiring harness, connectors or components, ensure service plug is removed and battery voltage or less exists at electrical connector. Use Toyota insulated gloves when touching any high-voltage wiring harness, connectors or components. Ensure insulated gloves are dry and in good condition and that no holes exist in insulated gloves. Test by applying air to insulated glove before touching any high-voltage wiring harness, connectors or components.

2002 ENGINE PERFORMANCE Theory & Operation

DO NOT wear any metal objects while working on vehicle which may accidently drop and cause a short circuit. If any high-voltage wiring harness connector is disconnected, ensure terminal on wiring harness connector is wrapped with tape to prevent wiring harness connector from contacting any surface. If servicing high-voltage system, place sign on roof of vehicle to indicate to other technicians that high-voltage system is being serviced.

2002 ENGINE PERFORMANCE Theory & Operation

Fig. 1: Locating Service Plug & Service Plug Assembly (Prius) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

AIR INDUCTION SYSTEMS

ACOUSTIC CONTROL INDUCTION SYSTEM

2002 ENGINE PERFORMANCE Theory & Operation

NOTE:

Acoustic Control Induction System (ACIS) may also be referred to as Intake Air Control Valve (IACV) system.

Avalon, Highlander 3.0L V6 & Sienna

Acoustic Control Induction System (ACIS) is a variable induction system that improves engine performance by increasing the length of intake runners in the air intake chamber. In accordance with engine speed and throttle opening angle, ACIS controls the length of intake runners in air intake chamber in 3 stages by opening and closing the 2 intake air control valves located on end of air intake chamber and downstream of the throttle valves. See Fig. 2 . When engine is under a heavy load and vehicle speed is low, Engine Control Module (ECM) turns on both ACIS Vacuum Switching Valves (VSVs) resulting in vacuum being supplied from vacuum tank to both actuators for the intake air control valves. ACIS VSVs may also be referred to as intake air control valve VSVs. This results in both intake air control valves closing, enabling the air intake chamber, throttle bodies and air cleaner hose to function as an intake manifold. When engine is under a medium load and vehicle speed in the mid-range, ECM turns on ACIS VSV at the air intake chamber side and turns off ACIS VSV downstream of the throttle valves. As a result, the intake air control valve in the air intake chamber closes and intake air control valve downstream of the throttle valves opens, enabling air intake chamber to function as the intake manifold. When engine is idling, engine is under a light load or vehicle speed is high, ECM turns off both ACIS VSVs. This allows both intake air control valves to open, enabling air intake chamber to function as a normal air intake chamber. ECM uses an engine RPM input signal and throttle position sensor input signal for determining ACIS operation. Engine RPM input signal is provided by camshaft and crankshaft position sensors.

Fig. 2: Locating Intake Air Control Valves (Avalon, Highlander 3.0L V6 & Sienna) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Camry 3.0L V6 & Camry Solara 3.0L V6

Acoustic Control Induction System (ACIS) is a variable induction system that improves engine performance

2002 ENGINE PERFORMANCE Theory & Operation

by increasing the length of intake runners in the air intake chamber. In accordance with engine speed and throttle opening angle, ACIS controls the length of intake runners in air intake chamber in 2 stages. This is accomplished by opening and closing the intake air control valve located on end of air intake chamber. See Fig. 3 and Fig. 4 . ACIS is controlled by Engine Control Module (ECM). ECM controls ACIS Vacuum Switching Valve (VSV) which controls vacuum supply from vacuum tank to the actuator. Actuator operates intake air control valve in air intake chamber. ECM uses engine RPM input signal and throttle position sensor input signal for determining ACIS operation. Engine RPM input signal is provided by camshaft and crankshaft position sensors.

Fig. 3: Locating Intake Air Control Valve (Camry 3.0L V6) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 ENGINE PERFORMANCE Theory & Operation

Fig. 4: Locating Intake Air Control Valve (Camry Solara 3.0L V6) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Celica

Acoustic Control Induction System (ACIS) is a variable induction system that improves engine performance and reduces engine noise by dividing the air intake duct into 2 stages. When engine is operating in low-tomid speed range, ACIS causes variable intake valve to close one side of the intake air duct. See Fig. 5 . When engine is operating in the high-speed range, ACIS causes variable intake valve to open, allowing both sides of the intake air duct to supply intake air. Variable intake valve operation is controlled by a vacuum controlled actuator. See Fig. 5 . Engine Control Module (ECM) controls the ACIS Vacuum Switching Valve (VSV) which controls vacuum supply from vacuum tank to the actuator. See Fig. 5 . ECM uses engine RPM input signal and throttle position sensor input signal for determining ACIS operation. Engine RPM input signal is provided by camshaft and crankshaft position sensors.

2002 ENGINE PERFORMANCE Theory & Operation

Fig. 5: Identifying Acoustic Control Induction System Components (Celica) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. AIR INTAKE CONTROL SYSTEM
Camry 3.0L V6

Air Intake Control System (AICS) reduces engine noise in low-speed ranges and increases engine performance in high-speed ranges by dividing air cleaner inlet into 2 stages. When engine is operating in low-to-mid speed range, AICS operates air intake control valve to close one side of air cleaner inlet. See Fig. 6 . When engine is operating in high-speed range, AICS operates air intake control valve to open both sides of air cleaner inlet to supply intake air. Air intake control valve operation is controlled by a vacuum controlled actuator. See Fig. 6 . Engine Control Module (ECM) controls Air Intake Control Valve (AICV)

2002 ENGINE PERFORMANCE Theory & Operation

Vacuum Switching Valve (VSV) which controls vacuum supply from vacuum tank to the actuator. See Fig. 6.

2002 ENGINE PERFORMANCE Theory & Operation

Fig. 6: Locating Air Intake Control System Components (Camry 3.0L V6) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ELECTRONIC THROTTLE CONTROL SYSTEM NOTE: Electronic Throttle Control System (ETCS) may also be referred to as Electronic Throttle Control System-Intelligent (ETCS-I or ETCS-i).

Camry 2.4L 4-Cyl. & Camry Solara 2.4L 4-Cyl.

Electronic Throttle Control System (ETCS) consists of throttle body, accelerator pedal position sensor, Throttle Position (TP) sensor, throttle control motor and Engine Control Module (ECM). ETCS uses the ECM to calculate throttle valve opening in the throttle body in relation to driving conditions. There is no accelerator cable used with the ETCS. ETCS controls idle speed and cruise control system operation. On A/T models, the throttle control is synchronized with the electronically controlled transaxle during shifting to reduce shift shock during transaxle shifting. On all models, accelerator pedal position sensor is mounted near accelerator pedal. See Fig. 7 . Accelerator pedal position sensor consists of 2 internal sensors which deliver accelerator pedal position input signals to the ECM to indicate throttle valve opening. TP sensor consists of 2 internal sensors which deliver input signals to ECM. ECM uses various input signals for operating throttle control motor. Throttle control motor is mounted on side of throttle body and operates throttle valve. See Fig. 7 . ETCS consists of various fail-safe features. If malfunction occurs in either one of the 2 internal sensors in accelerator pedal position sensor, the ECM detects the abnormal voltage signal difference between the 2 sensor circuits and switches to the limp mode. In limp mode, the remaining sensor circuit is used to calculate accelerator pedal position. If malfunction occurs in both internal sensors in accelerator pedal position sensor, the ECM detects the abnormal voltage signal difference between the 2 sensors circuits and regards that accelerator pedal is released and continues throttle control in which the vehicle may be driven at idle speed. If malfunction occurs in either one of the 2 internal sensors in TP sensor, the ECM detects the abnormal voltage signal difference between the 2 sensor circuits and switches to limp mode in which voltage to throttle control motor is turned off and throttle control motor becomes inoperative. Throttle return spring will position throttle valve at a designated position in which the vehicle may be driven. If problem exists with throttle control motor, ECM will switch to limp mode in which voltage to throttle control motor is turned off and throttle control motor becomes inoperative. Throttle return spring will position throttle valve at a designated position in which the vehicle may be driven. In the event of an ETCS malfunction, Malfunction Indicator Light (MIL) will be illuminated and Diagnostic Trouble Code (DTC) will be stored in ECM. MIL is displayed as an engine icon on instrument cluster on instrument panel. See TESTING PROCEDURE under SELF-DIAGNOSTIC SYSTEM in appropriate SELF-DIAGNOSTICS article for retrieval of DTCs.

2002 ENGINE PERFORMANCE Theory & Operation

Fig. 7: Locating Electronic Throttle Control System Components On Throttle Body & Accelerator Pedal Position Sensor (Camry 2.4L 4-Cyl. & Camry Solara 2.4L 4-Cyl.) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Camry 3.0L V6

Electronic Throttle Control System (ETCS) consists of throttle body, accelerator pedal position sensor, Throttle Position (TP) sensor, throttle control motor and Engine Control Module (ECM). ETCS uses the

2002 ENGINE PERFORMANCE Theory & Operation

ECM to calculate throttle valve opening in the throttle body in relation to driving conditions. There is no accelerator cable used with the ETCS. ETCS controls idle speed and cruise control system operation. On A/T models, the throttle control is synchronized with the electronically controlled transaxle during shifting to reduce shift shock during transaxle shifting. On models with traction control, the throttle valve is closed by demand signal from skid control Electronic Control Unit (ECU) if an excessive amount of slippage is created by a driving wheel. On models with vehicle skid control, throttle valve opening is controlled in conjunction with coordinating control with the skid control ECU to provide operation of vehicle skid control system. On all applications, accelerator pedal position sensor is mounted near accelerator pedal. See Fig. 8 . Accelerator pedal position sensor consists of 2 internal sensors which deliver accelerator pedal position signals to the ECM to indicate throttle valve opening. TP sensor consists of 2 internal sensors which delivers input signals to ECM. ECM uses various input signals for operating throttle control motor. Throttle control motor is mounted on side of throttle body and operates throttle valve. See Fig. 8 . ETCS consists of various fail-safe features. If malfunction occurs in either one of the 2 internal sensors in accelerator pedal position sensor, the ECM detects the abnormal voltage signal difference between the 2 sensor circuits and switches to the limp mode. In limp mode, the remaining sensor circuit is used to calculate accelerator pedal position. If malfunction occurs in both internal sensors in accelerator pedal position sensor, the ECM detects the abnormal voltage signal difference between the 2 sensors circuits and regards that accelerator pedal is released and continues throttle control in which the vehicle may be driven at idle speed. If malfunction occurs in either one of the 2 internal sensors in TP sensor, the ECM detects the abnormal voltage signal difference between the 2 sensor circuits and switches to limp mode in which voltage to throttle control motor is turned off and throttle control motor becomes inoperative. Throttle return spring will position throttle valve at a designated position in which the vehicle may be driven. If problem exists with throttle control motor, ECM will switch to limp mode in which voltage to throttle control motor is turned off and throttle control motor becomes inoperative. Throttle return spring will position throttle valve at a designated position in which the vehicle may be driven. In the event of an ETCS malfunction, Malfunction Indicator Light (MIL) will be illuminated and Diagnostic Trouble Code (DTC) will be stored in ECM. MIL is displayed as an engine icon on instrument cluster on instrument panel. See TESTING PROCEDURE under SELF-DIAGNOSTIC SYSTEM in appropriate SELF-DIAGNOSTICS article for retrieval of DTCs.

2002 ENGINE PERFORMANCE Theory & Operation

Fig. 8: Locating Electronic Throttle Control System Components On Throttle Body & Accelerator Pedal Position Sensor (Camry 3.0L V6) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Land Cruiser, Sequoia & Tundra 4.7L V8

Electronic Throttle Control System (ETCS) consists of throttle body, accelerator pedal position sensor, Throttle Position (TP) sensor, throttle control motor, magnetic clutch and Engine Control Module (ECM).

2002 ENGINE PERFORMANCE Theory & Operation

ETCS uses ECM to calculate throttle valve opening in the throttle body in relation to driving conditions. ETCS controls operation of idle speed control system, cruise control system, traction control system (if equipped) and vehicle skid control system (if equipped). Accelerator pedal position sensor is mounted on throttle body and is integrated with throttle lever which attaches to the throttle cable. See Fig. 9 . Accelerator pedal position sensor consists of 2 sensors which delivers input signals to the ECM. TP sensor delivers input signals to ECM to indicate throttle valve opening. ECM uses these input signals to operate throttle control motor to obtain proper operating speeds in relation to accelerator pedal position and engine speed, obtain proper idle speed, and operate cruise control system, traction control system (if equipped) and vehicle skid control system (if equipped). Throttle control motor is mounted on side of throttle body and operates throttle valve on throttle body by use of a magnetic clutch. In the event of an ETCS malfunction, Malfunction Indicator Light (MIL) will be illuminated and Diagnostic Trouble Code (DTC) will be stored in ECM. MIL is displayed as an engine icon on instrument cluster on instrument panel. See TESTING PROCEDURE under SELF-DIAGNOSTIC SYSTEM in appropriate SELF-DIAGNOSTICS article for retrieval of DTCs. If malfunction exists, magnetic clutch will be disengaged, allowing spring pressure to close the throttle valve. When magnetic clutch is disengaged, throttle control motor will not operate the throttle valve. If ETCS is shut off, accelerator pedal may be used to operate throttle valve for vehicle operation in limp mode by using limp mode lever on throttle body. See Fig. 9 .

Fig. 9: Locating Electronic Throttle Control System Components On Throttle Body (Land Cruiser, Sequoia & Tundra 4.7L V8) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
MR2 With Sequential Manual Transaxle & 4Runner

NOTE:

On MR2 models, 2 types of manual transaxles are used. Standard type

2002 ENGINE PERFORMANCE Theory & Operation

manual transaxle in which the driver operates the clutch and shifts the transaxle, and sequential manual transaxle, which is electronically controlled. Clutch is operated and transaxle is shifted hydraulically by moving shift lever forward or backward. Sequential manual transaxle may be identified by shift lever pattern which consists of "R", "N", "S" and "+" in place of the conventional type shift lever pattern and there is no clutch pedal. On all models, Electronic Throttle Control System (ETCS) consists of throttle body, accelerator pedal position sensor, Throttle Position (TP) sensor, throttle control motor, magnetic clutch and Engine Control Module (ECM). ETCS uses ECM to calculate throttle valve opening in the throttle body in relation to driving conditions. ETCS controls idle speed and cruise control system operation. Accelerator pedal position sensor is mounted on throttle body and is integrated with throttle lever which attaches to the throttle cable. See Fig. 10 and Fig. 11 . Accelerator pedal position sensor consists of 2 sensors which deliver input signals to the ECM. TP sensor delivers input signals to ECM to indicate throttle valve opening. ECM uses these input signals to operate throttle control motor to obtain proper operating speeds in relation to accelerator pedal position and engine speed, obtain proper idle speed, and provide cruise control operation. Throttle control motor is mounted on side of throttle body and operates throttle valve on throttle body by use of a magnetic clutch. In the event of an ETCS malfunction, Malfunction Indicator Light (MIL) will be illuminated and Diagnostic Trouble Code (DTC) will be stored in ECM. MIL is displayed as an engine icon on instrument cluster on instrument panel. See TESTING PROCEDURE under SELF-DIAGNOSTIC SYSTEM in appropriate SELF-DIAGNOSTICS article for retrieval of DTCs. If malfunction exists, magnetic clutch will be disengaged, allowing spring pressure to close the throttle valve. When magnetic clutch is disengaged, throttle control motor will not operate the throttle valve. If ETCS is shut off, accelerator pedal may be used to operate throttle valve for vehicle operation.

2002 ENGINE PERFORMANCE Theory & Operation

Fig. 10: Locating Electronic Throttle Control System Components On Throttle Body (MR2 With Sequential Manual Transaxle) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 ENGINE PERFORMANCE Theory & Operation

Fig. 11: Locating Electronic Throttle Control System Components On Throttle Body (4Runner) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Prius

Electronic Throttle Control System (ETCS) consists of throttle body, accelerator pedal position sensor, Throttle Position (TP) sensor, throttle control motor, Hybrid Vehicle (HV) control Electronic Control Unit (ECU) and Engine Control Module (ECM). Hybrid vehicle control ECU is referred to as HV ECU. ETCS uses ECM to calculate throttle valve opening in the throttle body in relation to driving conditions. ETCS controls idle speed and cruise control system operation. Accelerator pedal position sensor is mounted near accelerator pedal. See Fig. 12 . Accelerator pedal position sensor consists of 2 internal sensors which deliver accelerator pedal position input signals to the HV ECU. HV ECU in turn delivers the input signals to ECM. TP sensor delivers input signals to ECM to indicate throttle valve opening. ECM uses input signals to operate throttle control motor to obtain proper idle speed and provide cruise control operation. Throttle control motor is mounted on side of throttle body and operates throttle valve. See Fig. 12 . In the event of an ETCS malfunction, Malfunction Indicator Light (MIL) will be illuminated and Diagnostic Trouble Code (DTC) will be stored in ECM. MIL is displayed as an engine icon on instrument cluster at center of instrument panel. See TESTING PROCEDURE under SELF-DIAGNOSTIC SYSTEM in appropriate SELF-DIAGNOSTICS article for retrieval of DTCs. If malfunction exists, voltage to throttle control motor is turned off in which throttle control motor becomes inoperative, allowing spring pressure to close the throttle valve.

2002 ENGINE PERFORMANCE Theory & Operation

Fig. 12: Locating Electronic Throttle Control System Components On Throttle Body & Accelerator Pedal Position Sensor (Prius) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

COMPUTERIZED ENGINE CONTROLS

ENGINE CONTROL SYSTEM Engine control system is a computerized emission, ignition and fuel injection control system. Engine control system lowers exhaust emissions while maintaining good fuel economy and driveability. Engine control system consists of various sensors, switches and control units. See Fig. 13 -Fig. 33 . The Engine Control Module (ECM) controls engine control system based on input signals received from various input devices. ECM contains preprogrammed data to maintain optimum engine performance under all operating conditions.

2002 ENGINE PERFORMANCE Theory & Operation

Fig. 19: Locating Engine Control System Components (Corolla) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 20: Locating Engine Control System Components (ECHO) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 ENGINE PERFORMANCE Theory & Operation

Fig. 33: Locating Engine Control System Components (4Runner) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ENGINE IMMOBILIZER SYSTEM
Avalon, Camry, Camry Solara, Highlander, Land Cruiser, MR2, RAV4, Sequoia, Sienna & 4Runner

Engine immobilizer system is a theft deterrent system that disables engine from starting. This is accomplished by not allowing fuel injector and ignition system operation unless ignition key identification code matches code stored in Engine Control Module (ECM). Engine immobilizer system may be standard equipment on some models or optional equipment on other models. Models equipped with engine immobilizer system may be identified by looking at the ignition key. On models equipped with engine immobilizer system, the top of the ignition key is thicker than a standard ignition key, as a transponder chip is incorporated into the top of the ignition key. Engine immobilizer system consists of ignition key with transponder chip, transponder key coil, transponder key amplifier and ECM. When ignition key is inserted into ignition lock cylinder, the ECM instructs transponder key coil on ignition lock cylinder to supply an electromagnetic energy that enables transponder chip to transmit an ignition key identification code signal. Transponder key amplifier then amplifies ignition key identification code signal and delivers code signal to the ECM. ECM compares received ignition key identification code signal to code stored in the ECM. If ignition key identification code signal and code in the ECM match, ECM will allow fuel injector operation and ignition system operation. If ignition key identification code signal and code in the ECM do not match, ECM will not allow fuel injector operation and ignition system operation. For additional information on system operation and testing, see appropriate ENGINE IMMOBILIZER SYSTEMS article in ACCESSORIES & EQUIPMENT.
Prius

Engine immobilizer system may also be referred to as Hybrid Vehicle (HV) immobilizer system. Engine immobilizer system is a theft deterrent system that disables hybrid system and prevents engine from starting

2002 ENGINE PERFORMANCE Theory & Operation

by not allowing fuel injector and ignition system operation unless ignition key identification code matches code stored in Hybrid Vehicle (HV) control Electronic Control Unit (ECU). Hybrid vehicle control ECU is referred to as HV ECU. Engine immobilizer system consists of ignition key with transponder chip incorporated in top of ignition key, transponder key coil, transponder key ECU and HV ECU. When ignition is turned on, transponder key ECU checks if ignition key is registered and delivers the result to the HV ECU. When HV ECU confirms ignition key is registered, it transmits its own identification numbers to the transponder key ECU. The transponder ECU then calculates internally and delivers the calculated result back to the HV ECU. The HV ECU rechecks the calculated result against calculation stored in the HV ECU. If calculations are the same, the HV ECU allows hybrid system operation and allows the engine to start. If calculations are not the same, the HV ECU will not allow hybrid system operation and the engine to start. For additional information on system operation and testing, see appropriate ENGINE IMMOBILIZER SYSTEMS article in ACCESSORIES & EQUIPMENT. ENGINE CONTROL MODULE Engine Control Module (ECM) monitors and controls vehicle emissions, fuel system, ignition system and other various systems by using input signals from various input devices. ECM processes input signals from input devices and delivers output signals to various components for controlling system operation to achieve optimum engine performance for all operating conditions. See INPUT DEVICES and OUTPUT SIGNALS . ECM contains a fail-safe function which is used in case of sensor or switch failure. Fail-safe function uses preprogrammed values to provide a limp-in mode for minimal driveability. If a failure exists, ECM will inform the driver by illuminating the Malfunction Indicator Light (MIL). NOTE: MIL may also be referred to as CHECK ENGINE light. MIL is displayed as an engine icon on instrument cluster on instrument panel.

ECM contains a self-diagnostic system which may store a Diagnostic Trouble Code (DTC) if an electronic control system failure exists. DTC may be retrieved from ECM for system diagnosis by using Toyota handheld tester or a scan tool. See SELF-DIAGNOSTIC SYSTEMS . For ECM location, see Fig. 34 -Fig. 49 .

2002 ENGINE PERFORMANCE Theory & Operation

Fig. 39: Locating Engine Control Module (Corolla) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 ENGINE PERFORMANCE Theory & Operation

Fig. 49: Locating Engine Control Module (Tacoma 3.4L V6) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. HYBRID VEHICLE CONTROL ELECTRONIC CONTROL UNIT
Prius

Hybrid Vehicle (HV) control Electronic Control Unit (ECU) is used for controlling the hybrid system which uses the gasoline engine along with AC electric motor for vehicle operation. Hybrid vehicle control ECU is referred to as HV ECU. The HV ECU is located below carpet on floor panel, just below passenger's side of instrument panel. HV ECU receives input information from various sensors and electronic control units and determines the torque and output power. HV ECU delivers the demand torque and target RPM to ECM. The ECM uses this input information for controlling throttle opening, fuel injection system, ignition timing and Variable Valve Timing (VVT) system. The ECM delivers the actual engine RPM to the HV ECU. When vehicle is stopped, the HV ECU may deliver an input signal to the ECM to indicate that vehicle is stopped. ECM uses this for reducing fuel consumption. INPUT DEVICES Vehicles are equipped with different combinations of input devices. Not all devices are used on all models. Available input signals include the following:
Accelerator Pedal Position Sensor (Camry, Camry Solara 2.4L 4-Cyl., Land Cruiser, MR2 With Sequential Manual Transaxle, Sequoia, Tundra 4.7L V8 & 4Runner)

Accelerator pedal position sensor is used with Electronic Throttle Control System (ETCS) for controlling of

2002 ENGINE PERFORMANCE Theory & Operation

throttle operation. See ELECTRONIC THROTTLE CONTROL SYSTEM under AIR INDUCTION SYSTEMS for additional information.
Accelerator Pedal Position Sensor (Prius)

Accelerator pedal position sensor converts accelerator pedal angle into an electrical signal and delivers output signal to Hybrid Vehicle (HV) control Electronic Control Unit (ECU). Hybrid vehicle control ECU is referred to as HV ECU. The HV ECU communicates with the ECM for controlling the Electronic Throttle Control System (ETCS) for throttle operation. See ELECTRONIC THROTTLE CONTROL SYSTEM under AIR INDUCTION SYSTEMS for additional information.
A/C Compressor Lock Sensor (Camry)

A/C compressor lock sensor delivers 4 pulse input signals per engine revolution to Engine Control Module (ECM). If number ratio of A/C compressor speed divided by engine speed is smaller than a predetermined value, ECM delivers input signal to A/C amplifier and A/C amplifier will turn off A/C compressor. A/C lock sensor is located near front of A/C compressor.
A/C Compressor Lock Sensor (Camry Solara 2.4L 4-Cyl. With Manual A/C, Celica, Highlander, MR2 & RAV4)

A/C compressor lock sensor delivers a predetermined number of pulse input signals per engine revolution to Engine Control Module (ECM). If number ratio of A/C compressor speed divided by engine speed is smaller than a predetermined value, ECM will turn off A/C compressor. A/C lock sensor is located near front of A/C compressor.
A/C Evaporator Temperature Sensor (Camry 2.4L 4-Cyl. With Manual A/C & Camry Solara 2.4L 4-Cyl. With Manual A/C)

A/C evaporator temperature sensor may also be referred to as A/C thermistor. A/C evaporator temperature sensor detects temperature inside A/C cooling unit and delivers input signal to Engine Control Module (ECM). A/C evaporator temperature sensor is located inside A/C cooling unit, near A/C evaporator core.
A/C Switch (Avalon, Camry, Camry Solara, Celica, Corolla, ECHO, MR2, RAV4, Sequoia, Sienna, Tacoma, Tundra & 4Runner)

When A/C is turned on, input signal is delivered to Engine Control Module (ECM). ECM may use input signal for controlling engine operation. Input signal may be delivered from A/C switch, A/C amplifier, A/C control assembly or A/C clutch depending on model application.
Air/Fuel Sensor (Avalon, Camry, Camry Solara 2.4L 4-Cyl., Camry Solara 3.0L V6 With A/T, Highlander, RAV4, Sienna, Tacoma, Tundra 3.4L V6 & 4Runner)

Air Fuel (A/F) sensor may also be referred to as A/F ratio sensor. Heated A/F sensor monitors exhaust gas oxygen content and delivers an input signal to Engine Control Module (ECM). ECM may use input signal to control fuel injection system. For A/F sensor location, see A/F SENSOR LOCATION table. A/F SENSOR LOCATION Application Avalon Camry

Sensor Location One On Each Exhaust Manifold

2002 ENGINE PERFORMANCE Theory & Operation

2.4L 4-Cyl. 3.0L V6 Camry Solara 2.4L 4-Cyl. 3.0L V6 With A/T Highlander 2.4L 4-Cyl.

On Exhaust Manifold, Above Catalytic Converter One On Each Exhaust Manifold On Exhaust Manifold, Above Catalytic Converter One On Each Exhaust Manifold Two Sensors Are Used & Mounted On Exhaust Manifold, Above Catalytic Converters One On Each Exhaust Manifold Two Sensors Are Used & Mounted On Exhaust Manifold, Above Catalytic Converters One On Each Exhaust Manifold On Exhaust Pipe, In Front Of Catalytic Converter

3.0L V6 RAV4

Sienna Tacoma, Tundra 3.4L V6 & 4Runner

Airflow Meter (All Models)

NOTE:

Airflow meter may also be referred to as Mass Airflow (MAF) meter.

Airflow meter measures intake airflow volume. Input signal for airflow volume is sent from airflow meter to Engine Control Module (ECM). ECM may use input signal for determining ignition timing (spark advance), for controlling fuel injection system and oxygen sensor heater. Airflow meter also contains an intake air temperature sensor which is used to measure intake air temperature. See INTAKE AIR TEMPERATURE SENSOR .
Battery Signal (Avalon, Camry, Camry Solara, Celica, ECHO, Highlander, MR2, Prius, RAV4, Sienna, Tacoma, Tundra 3.4L V6 & 4Runner)

Battery voltage is always present at BATT terminal of Engine Control Module (ECM). When ignition is turned on, voltage for ECM operation is applied through EFI main relay to +B terminal on ECM. EFI main relay may also be referred to as EFI relay.
Battery Signal (Corolla)

Battery voltage is always present at BATT terminal of Engine Control Module (ECM). When ignition is turned on, voltage for ECM operation is applied through EFI main relay to +B terminal on ECM. EFI main relay may also be referred to as EFI relay or F-HTR relay.
Battery Signal (Land Cruiser)

Battery voltage is always present at BATT and +BM terminals of Engine Control Module (ECM). When ignition is turned on, voltage for ECM operation is applied through EFI main relay to +B and +B1 terminals on ECM. EFI main relay may also be referred to as EFI relay or ECD relay. Voltage is applied to IGSW terminal on ECM through IGN fuse.

2002 ENGINE PERFORMANCE Theory & Operation

Battery Signal (Sequoia & Tundra 4.7L V8)

Battery voltage is always present at BATT and +BM terminals of Engine Control Module (ECM). When ignition is turned on, voltage for ECM operation is applied through EFI main relay to +B and +B1 terminals on ECM. EFI main relay may also be referred to as EFI relay. Voltage is applied to IGSW terminal on ECM through IGN fuse or IGN1 fuse.
Brakelight Signal (Avalon, Camry, Camry Solara 2.4L 4-Cyl., Camry Solara 3.0L V6 With A/T, Celica With A/T, Corolla With 4-Speed A/T, ECHO With A/T, Highlander, Land Cruiser, MR2, RAV4, Sequoia, Sienna, Tacoma, Tundra With A/T & 4Runner)

Brakelight switch delivers an input signal to STP terminal of Engine Control Module (ECM) to indicate when brakes are applied. Input signal is mainly used for controlling fuel cut-off engine speed, as fuel cut-off engine speed is slightly reduced when brakes are applied. Brakelight switch may also be referred to as stoplight switch.
Camshaft & Crankshaft Position Sensors (Avalon, Highlander 3.0L V6 & Sienna)

Camshaft position sensors and crankshaft position sensor deliver input signals to Engine Control Module (ECM). Camshaft position sensors may also be referred to Variable Valve Timing (VVT) sensors. Camshaft position sensors are located at flywheel end of each cylinder head, just below valve cover. Crankshaft position sensor is located at front of crankshaft, near crankshaft pulley. ECM may use input signals for determining ignition timing (spark advance), and for controlling fuel injection system, engine idle speed control system, Acoustic Control Induction System (ACIS) and VVT system.
Camshaft & Crankshaft Position Sensors (Camry 2.4L 4-Cyl. & Camry Solara 2.4L 4-Cyl.)

Camshaft position sensor and crankshaft position sensor deliver input signals to Engine Control Module (ECM). Camshaft position sensor may also be referred to as Variable Valve Timing (VVT) sensor. Camshaft position sensor is located on end of cylinder head at flywheel end of engine. Crankshaft position sensor is located on front of engine, near crankshaft pulley. ECM may use input signals for determining ignition timing (spark advance), and for controlling fuel injection system and VVT system.
Camshaft & Crankshaft Position Sensors (Camry 3.0L V6 & Camry Solara 3.0L V6)

Camshaft position sensor and crankshaft position sensor deliver input signals to Engine Control Module (ECM). Camshaft position sensor is located at flywheel end of front (radiator side) cylinder head, just below valve cover. Crankshaft position sensor is located at front of crankshaft, near crankshaft pulley. ECM may use input signals for determining ignition timing (spark advance), and for controlling fuel injection system, engine idle speed control system, EGR system, heated oxygen sensor system and Acoustic Control Induction System (ACIS).
Camshaft & Crankshaft Position Sensors (Celica, Corolla, ECHO, Highlander 2.4L 4-Cyl., MR2, Prius & RAV4)

Camshaft position sensor and crankshaft position sensor deliver input signals to Engine Control Module (ECM). Camshaft position sensor may also be referred to as Variable Valve Timing (VVT) sensor. On Celica, Corolla and MR2, camshaft position sensor is located just above intake manifold on cylinder head, at flywheel end of engine. On ECHO, Highlander, Prius and RAV4, camshaft position sensor is located on end of cylinder head at flywheel end of engine. On all models, crankshaft position sensor is located on front of engine, near crankshaft pulley. ECM may use input signals for determining ignition timing (spark advance), and for controlling fuel injection system, engine idle speed control system and VVT system.

2002 ENGINE PERFORMANCE Theory & Operation

Camshaft & Crankshaft Position Sensors (Land Cruiser & Sequoia)

Camshaft position sensor and crankshaft position sensor deliver input signals to Engine Control Module (ECM). Camshaft position sensor is located behind driver's side upper timing belt cover, near camshaft sprocket. Crankshaft position sensor is located at front of crankshaft, near crankshaft pulley. ECM may use input signals for determining ignition timing (spark advance) and for controlling fuel injection system.
Camshaft & Crankshaft Position Sensors (Tacoma 2.4L 4-Cyl. & 2.7L 4-Cyl.)

Camshaft position sensor and crankshaft position sensor deliver input signals to Engine Control Module (ECM). Camshaft position sensor is located at driver's side front corner of cylinder head, just in front of intake manifold. Crankshaft position sensor is located near crankshaft pulley, just above oil pan on driver's side of engine. ECM may use input signals for determining ignition timing (spark advance), and for controlling fuel injection system and heated oxygen sensor system.
Camshaft & Crankshaft Position Sensors (Tacoma 3.4L V6, Tundra 3.4L V6 & 4Runner)

Camshaft position sensor and crankshaft position sensor deliver input signals to Engine Control Module (ECM). Camshaft position sensor is located behind upper timing belt cover, near passenger's side camshaft sprocket. Crankshaft position sensor is located at front of engine, just above crankshaft pulley. ECM may use input signals for determining ignition timing (spark advance), and for controlling fuel injection system and heated oxygen sensor system.
Camshaft & Crankshaft Position Sensors (Tundra 4.7L V8)

Camshaft position sensor and crankshaft position sensor deliver input signals to Engine Control Module (ECM). Camshaft position sensor is located behind driver's side upper timing belt cover, near camshaft sprocket. Crankshaft position sensor is located at front of crankshaft, near crankshaft pulley. ECM may use input signals for determining ignition timing (spark advance) and for controlling fuel injection system.
Center Air Bag Sensor Assembly (Celica, Corolla, Highlander, MR2, RAV4, Sequoia & Sienna)

Center air bag sensor assembly delivers an input signal to Engine Control Module (ECM) if an airbag is deployed. If ECM detects that air bags are deployed, ECM will stop fuel pump operation by opening the circuit opening relay. This operation is referred to as fuel cut control. If fuel cut control has been activated, turning ignition switch from OFF position to ON position cancels the fuel cut control operation and fuel pump will operate. Center air bag sensor assembly may also be referred to as air bag sensor assembly.
Center Air Bag Sensor Assembly (Prius)

Center air bag sensor assembly delivers an input signal to Hybrid Vehicle (HV) control Electronic Control Unit (ECU) if an airbag is deployed. Hybrid vehicle control ECU is referred to as HV ECU. The HV ECU then delivers input signal to Engine Control Module (ECM). If air bags are deployed, ECM will stop fuel pump operation by opening the circuit opening relay. This operation is referred to fuel cut control. If fuel cut control has been activated, turning ignition switch from OFF position to ON position cancels the fuel cut control operation and fuel pump will operate. Center air bag sensor assembly may also be referred to as air bag sensor assembly.
EGR Gas Temperature Sensor (Camry 3.0L V6, Camry Solara 3.0L V6 & Tacoma 2.7L 4-Cyl. 3RZ-FE)

EGR gas temperature sensor monitors EGR gas temperature and delivers an input signal to Engine Control Module (ECM). EGR gas temperature sensor is located near EGR valve.

2002 ENGINE PERFORMANCE Theory & Operation

EGR Position Sensor (Camry 3.0L V6 & Camry Solara 3.0L V6)

EGR position sensor monitors movement of EGR valve and delivers an input signal to Engine Control Module (ECM). ECM uses this input signal to obtain the correct amount of EGR valve opening in relation to the engine operation. EGR position sensor may also be referred to as EGR valve position sensor. EGR position sensor is mounted on EGR valve.
Electrical Load Signal (Avalon, Camry, Camry Solara, Corolla & Sienna)

An input signal is delivered to ELS and ELS2 terminals of Engine Control Module (ECM) to indicate when high electrical output is required. This signal is delivered when items such as headlights or rear window defroster are turned on. ECM may use input signal to maintain proper engine idle speed.
Electrical Load Signal (ECHO)

On vehicles equipped for cold areas, an input signal is delivered to ELS terminal of Engine Control Module (ECM) to indicate when high electrical output is required. This may occur when HTR SUB1 relay is energized to provide voltage to Positive Temperature Coefficient (PTC) heater. PTC heater is a small electrical heater located in the heater core. PTC heater will be turned on when engine coolant temperature is less than 176F (80C), engine speed is greater than 1050 RPM, generator power ratio is less than 95 percent and heater temperature control switch is positioned in maximum heat range. ECM may use input signal to maintain proper engine idle speed.
Electrical Load Signal (Land Cruiser, RAV4, Sequoia, Tacoma 2.4L 4-Cyl. & 2.7L 4-Cyl., & Tundra 4.7L V8)

An input signal is delivered to ELS terminal of Engine Control Module (ECM) to indicate when high electrical output is required. This signal is delivered when items such as rear window defroster or headlights are turned on. ECM may use input signal to maintain proper engine idle speed.
Engine Coolant Temperature Sensor (All Models)

Engine Coolant Temperature (ECT) sensor contains a built-in thermistor in which resistance varies according to engine coolant temperature. ECT delivers an input signal to THW terminal of Engine Control Module (ECM). ECM may use input signal for determining ignition timing (spark advance), and for controlling fuel injection system, engine idle speed control system, heated oxygen sensor system (if equipped), EGR system (if equipped) and operation of electronically controlled transaxles/transmissions (if equipped). For ECT sensor location, see ENGINE COOLANT TEMPERATURE SENSOR under ENGINE SENSORS & SWITCHES in appropriate REMOVAL, OVERHAUL & INSTALLATION article.
Engine Cranking Signal (Avalon, Camry, Camry Solara, Celica, Corolla, ECHO, Highlander, Land Cruiser, MR2, RAV4, Sequoia, Sienna, Tacoma, Tundra & 4Runner)

While engine is cranking and voltage is applied to the starter, an input signal is also delivered to STA or NSW terminal of Engine Control Module (ECM). ECM may use input signal for determining ignition timing (spark advance) and for controlling fuel injection system.
Heated Oxygen Sensor (All Models)

Heated oxygen sensor monitors exhaust gas oxygen content and delivers an input signal to Engine Control Module (ECM). ECM may use input signal for determining ignition timing (spark advance) and for controlling fuel injection system. Some models may be equipped with more than one heated oxygen sensor.

2002 ENGINE PERFORMANCE Theory & Operation

A heater is used to warm oxygen sensor to improve heated oxygen sensor detection operation. Heater is controlled by ECM.
Intake Air Temperature Sensor (All Models)

Intake air temperature sensor is located in airflow meter. Intake air temperature sensor measures incoming intake air temperature and delivers an input signal to THA terminal of Engine Control Module (ECM). ECM may use input signal for determining ignition timing (spark advance) and for controlling fuel injection system.
Knock Sensor (Avalon, Camry 3.0L V6, Camry Solara 3.0L V6, Highlander 3.0L V6, Land Cruiser, Sequoia, Sienna & Tundra 4.7L V8)

Knock sensors No. 1 and 2 monitor ignition knock conditions and deliver input signals to KNKR and KNKL terminals of Engine Control Module (ECM). ECM may use input signals for determining ignition timing (spark advance) and for controlling fuel injection system. For knock sensor location, see KNOCK SENSOR under ENGINE SENSORS & SWITCHES in REMOVAL, OVERHAUL & INSTALLATION - V6 & V8 article.
Knock Sensor (Camry 2.4L 4-Cyl., Camry Solara 2.4L 4-Cyl., Celica, Corolla, ECHO, Highlander 2.4L 4Cyl., MR2, Prius, RAV4 & Tacoma 2.4L 4-Cyl. & 2.7L 4-Cyl.)

Knock sensor monitors ignition knock conditions and delivers input signal to KNK1 terminal of Engine Control Module (ECM). ECM may use input signal for determining ignition timing (spark advance) and for controlling fuel injection system. For knock sensor location, see KNOCK SENSOR under ENGINE SENSORS & SWITCHES in REMOVAL, OVERHAUL & INSTALLATION - 4-CYLINDER article.
Knock Sensor (Tacoma 3.4L V6, Tundra 3.4L V6 & 4Runner)

Knock sensors No. 1 and 2 monitor ignition knock conditions and deliver input signals to KNK1 and KNK2 terminals of Engine Control Module (ECM). ECM may use input signal for determining ignition timing (spark advance) and for controlling fuel injection system. For knock sensor location, see KNOCK SENSOR under ENGINE SENSORS & SWITCHES in REMOVAL, OVERHAUL & INSTALLATION - V6 & V8 article.
Park/Neutral Position Switch (Avalon, Camry, Camry Solara, Celica, Corolla, ECHO, Highlander, Land Cruiser, RAV4, Sequoia, Sienna, Tacoma, Tundra & 4Runner)

Park/Neutral Position (PNP) switch is used only on A/T models. PNP switch delivers an input signal to Engine Control Module (ECM) to indicate transaxle or transmission gear position. ECM may use input signal to control engine idle speed and fuel injection system. PNP switch is located on side of transaxle or transmission.
Park/Neutral Position Switch (Prius)

Park/Neutral Position (PNP) switch is used only for the hybrid vehicle control system which controls the electric transaxle. PNP switch delivers an input signal to Hybrid Vehicle (HV) control Electronic Control Unit (ECU) to indicate transaxle gear position instead of the Engine Control Module (ECM) like all other models. Hybrid vehicle control ECU is referred to as HV ECU. The HV ECU uses input signal for controlling vehicle movement. PNP switch is located on end of shift lever assembly on steering column and may also be referred to as shift position sensor.

2002 ENGINE PERFORMANCE Theory & Operation

Power Steering Pressure Sensor (ECHO)

Power steering pressure sensor delivers an input signal to ECM to indicate power steering pressure. ECM may use input signal to control engine idle speed. Power steering pressure sensor may also be referred to as power steering oil pressure sensor. Power steering pressure sensor is located on side of power steering pump.
Power Steering Pressure Switch (Avalon, Camry, Camry Solara, Celica, Corolla, Highlander, RAV4, Sienna, Tacoma, Tundra 3.4L V6 & 4Runner)

Power steering pressure switch delivers an input signal to Engine Control Module (ECM) to indicate power steering pressure. ECM may use input signal to control engine idle speed. Power steering pressure switch may also be referred to as power steering oil pressure switch. Power steering pressure switch is located on power steering pump or near pressure hose at power steering pump.
Temperature Control Switch (ECHO)

On vehicles equipped for cold areas, temperature control switch operates a maximum hot switch which provides an input signal to Engine Control Module (ECM) for controlling Positive Temperature Coefficient (PTC) heater. PTC heater is a small electrical heater located in the heater core. Maximum hot switch may also be referred to as MAX HOT switch. For additional information on PTC heater, see POSITIVE TEMPERATURE COEFFICIENT HEATER under MISCELLANEOUS CONTROLS.
Throttle Position Sensor (Avalon, Camry Solara 3.0L V6, Celica, Corolla, ECHO, Highlander, MR2 With Standard Type Manual Transaxle, RAV4, Sienna, Tacoma & Tundra 3.4L V6)

Throttle Position (TP) sensor is located on throttle body. TP sensor delivers an input signal indicating throttle position to Engine Control Module (ECM). ECM may use input signal for determining ignition timing (spark advance), and for controlling fuel injection system, idle speed control system and various other systems.
Throttle Position Sensor (Camry, Camry Solara 2.4L 4-Cyl., Land Cruiser, MR2 With Sequential Manual Transaxle, Prius, Sequoia, Tundra 4.7L V8 & 4Runner)

Throttle Position (TP) sensor is used with Electronic Throttle Control System (ETCS) for control of the throttle operation. See ELECTRONIC THROTTLE CONTROL SYSTEM under AIR INDUCTION SYSTEMS for additional information.
Vacuum Sensor For Hydrocarbon Adsorber Catalyst System (Prius)

Vacuum sensor provides input signal to Engine Control Module (ECM). ECM uses input signal for controlling the Hydrocarbon Adsorber Catalyst (HCAC) system. For additional information on HCAC system, see HYDROCARBON ADSORBER CATALYST SYSTEM under EMISSION SYSTEMS & SUB-SYSTEMS. Vacuum sensor is located at passenger's side front corner of the engine. See Fig. 50 .

2002 ENGINE PERFORMANCE Theory & Operation

Fig. 50: Locating Vacuum Sensor For HCAC System (Prius) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Vapor Pressure Sensor (Avalon, Camry, Camry Solara, Celica, Corolla, Highlander, MR2, RAV4, Sequoia, Sienna, Tacoma & 4Runner)

Vapor pressure sensor, pressure switching valve Vacuum Switching Valve (VSV) and canister closed valve Vacuum Switching Valve (VSV) are used to determine if a leak or an abnormality exists in the EVAP system. See Fig. 51 . EVAP system may also be referred to as fuel evaporative system. Engine Control Module (ECM) determines if a leak or an abnormality exists in EVAP system by using input signal from vapor pressure sensor. If a leak or abnormality exists, a Diagnostic Trouble Code (DTC) will be stored in the ECM. Vapor pressure sensor may also be referred to as EVAP vapor pressure sensor. Canister closed valve

2002 ENGINE PERFORMANCE Theory & Operation

VSV may also be referred to as EVAP Canister Closed Valve Vacuum Switching Valve (EVAP-CCVVSV) or Canister Closed Valve Vacuum Switching Valve (CCV VSV). Pressure switching valve VSV may also be referred to as EVAP Pressure Switching Valve Vacuum Switching Valve (EVAP-PSVVSV). EVAP canister may also be referred to as charcoal canister.

Fig. 51: Identifying Typical EVAP System Components (Avalon, Camry, Camry Solara, Celica, Corolla, ECHO, Highlander, MR2, RAV4, Sequoia, Sienna, Tacoma & 4Runner) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Vapor Pressure Sensor (ECHO)

Vapor pressure sensor and canister closed valve Vacuum Switching Valve (VSV) are used to determine if a leak or an abnormality exists in the EVAP system. See Fig. 51 . EVAP system may also be referred to as fuel evaporative system. Engine Control Module (ECM) determines if a leak or an abnormality exists in EVAP system by using input signal from vapor pressure sensor. If a leak or abnormality exists, a DTC will be stored in the ECM. Vapor pressure sensor may also be referred to as EVAP vapor pressure sensor. Canister closed valve VSV may also be referred to as EVAP Canister Closed Valve Vacuum Switching Valve (EVAP-CCVVSV) or Canister Closed Valve Vacuum Switching Valve (CCV VSV). EVAP canister may also be referred to as charcoal canister.
Vapor Pressure Sensor (Land Cruiser & Tundra)

Vapor pressure sensor and vapor pressure sensor Vacuum Switching Valve (VSV) are used to determine if a leak or an abnormality exists in the EVAP system. See Fig. 52 . Engine Control Module (ECM) determines if a leak or an abnormality exists in EVAP system by using input signal from vapor pressure sensor. EVAP system may also be referred to as fuel evaporative system. Vapor pressure sensor may also be referred to as EVAP vapor pressure sensor. Vapor pressure sensor VSV may also be referred to as EVAP Vapor Pressure Sensor Vacuum Switching Valve (EVAP-VPSVSV).

2002 ENGINE PERFORMANCE Theory & Operation

Fig. 52: Identifying Typical EVAP System Components (Land Cruiser & Tundra) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Vapor Pressure Sensor (Prius)

Vapor pressure sensor, purge flow switching valve Vacuum Switching Valve (VSV) and canister closed valve Vacuum Switching Valve (VSV) are used to determine if a leak or an abnormality exists in the EVAP system. See Fig. 53 . EVAP system may also be referred to as fuel evaporative system. Engine Control Module (ECM) determines if a leak or an abnormality exists in EVAP system by using input signal from vapor pressure sensor. If a leak or abnormality exists, a Diagnostic Trouble Code (DTC) will be stored in the ECM. Vapor pressure sensor may also be referred to as EVAP vapor pressure sensor. Canister closed valve VSV may also be referred to as EVAP Canister Closed Valve Vacuum Switching Valve (EVAP-CCVVSV) or Canister Closed Valve Vacuum Switching Valve (CCV VSV). Purge flow switching valve VSV may also be referred to as EVAP Purge Flow Switching Valve Vacuum Switching Valve (EVAP-PFSVVSV). EVAP canister may also be referred to as charcoal canister.

2002 ENGINE PERFORMANCE Theory & Operation

Fig. 53: Identifying EVAP System Components (Prius) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Variable Valve Timing Sensor (Avalon, Highlander 3.0L V6 & Sienna)

See CAMSHAFT & CRANKSHAFT POSITION SENSORS (AVALON, HIGHLANDER 3.0L V6 & SIENNA) .
Variable Valve Timing Sensor (Camry 2.4L 4-Cyl. & Camry Solara 2.4L 4-Cyl.)

See CAMSHAFT & CRANKSHAFT POSITION SENSORS (CAMRY 2.4L 4-CYL. & CAMRY SOLARA 2.4L 4-CYL.) .
Variable Valve Timing Sensor (Celica, Corolla, ECHO, Highlander 2.4L 4-Cyl., MR2, Prius & RAV4)

See CAMSHAFT & CRANKSHAFT POSITION SENSORS (CELICA, COROLLA, ECHO, HIGHLANDER 2.4L 4-CYL., MR2, PRIUS & RAV4) .
Vehicle Speed Sensor (Avalon)

Wheel speed sensors on each wheel deliver an input signal to Anti-Lock Brake System (ABS) Electronic Control Unit (ECU). ABS ECU converts input signals from wheel speed sensors to a 4-pulse input signal to the instrument cluster. Instrument cluster then converts 4-pulse input signal to a rectangular waveform and then sends input signal to Engine Control Module (ECM). ECM determines vehicle speed by using input

2002 ENGINE PERFORMANCE Theory & Operation

signal. ECM may use input signal for controlling fuel injection system, electronically controlled automatic transaxle and various other systems. On models with traction control, ABS ECU may also be referred to as ABS & BA (Brake Assist) & TRAC & Vehicle Skid Control (VSC) ECU. On models without traction control, ABS ECU may also be referred to as ABS actuator and ECU.
Vehicle Speed Sensor (Camry 2.4L 4-Cyl.)

Vehicle speed sensor is mounted near rear of transaxle. Vehicle speed sensor outputs a 4-pulse input signal for every revolution of the drive gear in transaxle to the instrument cluster where input signal is converted to a rectangular waveform and then sent to Engine Control Module (ECM). ECM determines vehicle speed by using input signal. ECM may use input signal for controlling fuel injection system, electronically controlled automatic transaxle (if equipped) and various other systems.
Vehicle Speed Sensor (Camry 3.0L V6)

Wheel speed sensors on each wheel deliver an input signal to skid control Electronic Control Unit (ECU). Skid control ECU converts input signals from wheel speed sensors to a 4-pulse input signal to the instrument cluster. Instrument cluster then converts 4-pulse input signal to a rectangular waveform and then sends input signal to Engine Control Module (ECM). ECM determines vehicle speed by using input signal. ECM may use input signal for controlling fuel injection system, electronically controlled automatic transaxle and various other systems.
Vehicle Speed Sensor (Camry Solara, Celica, Corolla, ECHO, Land Cruiser, RAV4, Sequoia, Tacoma & Tundra)

Vehicle speed sensor is mounted near rear of transaxle or transmission. Vehicle speed sensor outputs a 4pulse input signal for every revolution of the drive gear in transaxle or transmission to the instrument cluster where input signal is converted to a rectangular waveform and then sent to Engine Control Module (ECM). ECM determines vehicle speed by using input signal. ECM may use input signal for controlling fuel injection system, electronically controlled automatic transaxle or transmission (if equipped) and various other systems.
Vehicle Speed Sensor (Highlander)

Wheel speed sensors on each wheel deliver an input signal to skid control Electronic Control Unit (ECU). Skid control ECU converts input signals from wheel speed sensors to a 4-pulse input signal to the instrument cluster. Instrument cluster then converts 4-pulse input signal to a rectangular waveform and then sends input signal to Engine Control Module (ECM). ECM determines vehicle speed by using input signal. ECM may use input signal for controlling fuel injection system, electronically controlled automatic transaxle and various other systems.
Vehicle Speed Sensor (MR2)

Wheel speed sensors on each wheel deliver an input signal to Anti-Lock Brake System (ABS) Electronic Control Unit (ECU). ABS ECU converts input signals from wheel speed sensors to a 4-pulse input signal to the instrument cluster. Instrument cluster then converts 4-pulse input signal to a rectangular waveform and then sends input signal to Engine Control Module (ECM). ECM determines vehicle speed by using input signal. ECM uses input signal for controlling fuel injection system, electronically controlled automatic transaxle and various other systems.
Vehicle Speed Sensor (Prius)

2002 ENGINE PERFORMANCE Theory & Operation

Wheel speed sensors on each wheel deliver an input signal to brake Electronic Control Unit (ECU) for the Anti-Lock Brake System (ABS). Brake ECU converts input signals from wheel speed sensors to a 4-pulse input signal to the instrument cluster. Instrument cluster then converts 4-pulse input signal to a rectangular waveform and then sends input signal to Engine Control Module (ECM). ECM determines vehicle speed by using input signal. ECM may use input signal for controlling fuel injection system and vehicle operation.
Vehicle Speed Sensor (Sienna)

Wheel speed sensors on each wheel deliver an input signal to Anti-Lock Brake System (ABS) Electronic Control Unit (ECU). ABS ECU converts input signals from wheel speed sensors to a 4-pulse input signal to the instrument cluster. Instrument cluster then converts 4-pulse input signal to a rectangular waveform and then sends input signal to Engine Control Module (ECM). ECM determines vehicle speed by using input signal. ECM may use input signal for controlling fuel injection system, electronically controlled automatic transaxle and various other systems. On models with Vehicle Skid Control (VSC), ABS ECU may also be referred to as VSC ECU. On models without VSC, ABS ECU may also be referred to as ABS actuator and ECU.
Vehicle Speed Sensor (4Runner)

Wheel speed sensors on each wheel deliver an input signal to Vehicle Skid Control (VSC) Electronic Control Unit (ECU). VSC ECU converts input signals from wheel speed sensors to a 4-pulse input signal to the instrument cluster. Instrument cluster then converts 4-pulse input signal to a rectangular waveform and then sends input signal to Engine Control Module (ECM). ECM determines vehicle speed by using input signal. ECM may use input signal for controlling fuel injection system, electronically controlled automatic transmission and various other systems.
4WD Input (Land Cruiser, Sequoia, Tacoma, Tundra & 4Runner)

On 4WD models, Engine Control Module (ECM) receives an input signal from transfer L4 position switch and transfer neutral position switch to indicate transfer case position. OUTPUT SIGNALS NOTE: Vehicles are equipped with different combinations of computer-controlled components. Not all components listed below are used on every vehicle. For theory and operation on each output component, refer to system indicated after component.

Engine Control Module (ECM) receives input from data sensors and switches, depending on model application, to control following components and sub-systems:
Accelerator Pedal Position Sensor

See ELECTRONIC THROTTLE CONTROL SYSTEM under AIR INDUCTION SYSTEMS.

Acoustic Control Induction System

See ACOUSTIC CONTROL INDUCTION SYSTEM under AIR INDUCTION SYSTEMS.

Acoustic Control Induction System Vacuum Switching Valve

2002 ENGINE PERFORMANCE Theory & Operation

See ACOUSTIC CONTROL INDUCTION SYSTEM under AIR INDUCTION SYSTEMS.

Active Control Mount Vacuum Switching Valve

See ACTIVE CONTROL ENGINE MOUNT under MISCELLANEOUS CONTROLS.

A/C-Cut Control System

See IDLE SPEED under FUEL SYSTEMS.

A/F Heater Relay

See FUEL DELIVERY under FUEL SYSTEMS.

Air Intake Control Valve (AICV) Vacuum Switching Valve (VSV)

See AIR INTAKE CONTROL SYSTEM under AIR INDUCTION SYSTEMS.

Canister Closed Valve Vacuum Switching Valve

See FUEL EVAPORATIVE SYSTEM under EMISSION SYSTEMS & SUB-SYSTEMS.

Circuit Opening Relay

See FUEL DELIVERY under FUEL SYSTEMS.

EGR Vacuum Switching Valve

See EXHAUST GAS RECIRCULATION CONTROL under EMISSION SYSTEMS & SUB-SYSTEMS.
Electronically Controlled Transmission/Transaxle

See TRANSMISSION/TRANSAXLE CONTROLS under MISCELLANEOUS CONTROLS.

Electronic Spark Advance System

See DISTRIBUTORLESS IGNITION SYSTEM under IGNITION SYSTEMS.

EVAP Vacuum Switching Valve

See FUEL EVAPORATIVE SYSTEM under EMISSION SYSTEMS & SUB-SYSTEMS.

Fuel Pump

See FUEL DELIVERY under FUEL SYSTEMS.

Fuel Pump Relay

See FUEL DELIVERY under FUEL SYSTEMS.

Hydrocarbon Adsorber Catalyst System Vacuum Switching Valve

2002 ENGINE PERFORMANCE Theory & Operation

See HYDROCARBON ADSORBER CATALYST SYSTEM under EMISSION SYSTEMS & SUBSYSTEMS.
HRT SUB1 Relay

See POSITIVE TEMPERATURE COEFFICIENT HEATER under MISCELLANEOUS CONTROLS.

Idle Speed Control System

See IDLE SPEED under FUEL SYSTEMS.

IG2 Relay

See IG2 RELAY under MISCELLANEOUS CONTROLS.

Pressure Switching Valve Vacuum Switching Valve

See FUEL EVAPORATIVE SYSTEM under EMISSION SYSTEMS & SUB-SYSTEMS.

Purge Flow Switching Valve Vacuum Switching Valve

See FUEL EVAPORATIVE SYSTEM under EMISSION SYSTEMS & SUB-SYSTEMS.

Self-Diagnostic System

See SELF-DIAGNOSTIC SYSTEMS .

Throttle Control Motor

See ELECTRONIC THROTTLE CONTROL SYSTEM under AIR INDUCTION SYSTEMS.

Vapor Pressure Sensor Vacuum Switching Valve

See FUEL EVAPORATIVE SYSTEM under EMISSION SYSTEMS & SUB-SYSTEMS.

Variable Valve Lift Oil Control Valve

Variable Valve Lift (VVL) oil control valve may also be referred to as Oil Control Valve (OCV). See VARIABLE VALVE LIFT SYSTEM .
Variable Valve Timing Camshaft Timing Oil Control Valve

Variable Valve Timing (VVT) camshaft timing oil control valve may also be referred to as oil control valve or VVT Oil Control Valve (OCV). See VARIABLE VALVE TIMING SYSTEM .

FUEL SYSTEMS
FUEL DELIVERY
A/F Heater Relay (Avalon, Camry 3.0L V6, Camry Solara 3.0L V6 With A/T, Highlander & Sienna)

2002 ENGINE PERFORMANCE Theory & Operation

A/F heater relay may also be referred to as A/F HTR relay, A/F sensor relay or A/F relay. Constant battery voltage is supplied from battery, through A/F heater fuse to one side of A/F heater relay. A/F heater fuse may also be referred to as A/F fuse. A/F heater relay is energized by MREL terminal of Engine Control Module (ECM). When A/F heater relay is energized, A/F heater relay provides battery voltage to +B terminal at Air Fuel (A/F) sensors. For A/F heater relay location, see A/F HEATER RELAY LOCATION table.

Fig. 54: Locating A/F Heater Relay (Sienna) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
A/F Heater Relay (RAV4)

A/F heater relay may also be referred to as A/F HTR relay, A/F sensor relay or A/F relay. Constant battery voltage is supplied from battery, through A/F heater fuse to one side of A/F heater relay. A/F heater fuse may also be referred to as A/F fuse. When EFI main relay is energized, voltage is supplied to other side of A/F heater relay and A/F heater relay is energized. When A/F heater relay is energized, A/F heater relay provides battery voltage to +B terminal at Air Fuel (A/F) sensors. For A/F heater relay location, see A/F HEATER RELAY LOCATION table.

2002 ENGINE PERFORMANCE Theory & Operation

A/F HEATER RELAY LOCATION Application Avalon & Camry Camry Solara Highlander RAV4 Sienna

Location In Fuse/Relay Box At Driver's Side Front Corner Of Engine Compartment In Small Fuse/Relay Box At Driver's Side Front Corner Of Engine Compartment, In Front Of Battery In Fuse/Relay Box At Driver's Side Front Corner Of Engine Compartment, Just In Front Of Strut Tower In Fuse/Relay Box At Driver's Side Front Corner Of Engine Compartment
(1)

(1) Located near Engine Control Module (ECM) behind passenger's side of instrument panel and

contains a 4-pin connector. See Fig. 54 .

Circuit Opening Relay (Avalon)

Circuit opening relay controls fuel pump circuit. When EFI main relay is energized, it provides battery voltage to one side of circuit opening relay. When ignition is turned on, voltage is supplied from ignition switch to other side of circuit opening relay. When proper input signals are delivered to Engine Control Module (ECM), circuit opening relay ground circuit is grounded at ECM terminal FC. Circuit opening relay then provides voltage to fuel pump for fuel pump operation. For circuit opening relay location, see CIRCUIT OPENING RELAY LOCATION table. Circuit opening relay may also be identified by appropriate illustration in appropriate SYSTEM & COMPONENT TESTING article.
Circuit Opening Relay (Camry)

Circuit opening relay controls fuel pump circuit. When EFI main relay is energized, it provides battery voltage to one side of circuit opening relay. When ignition is turned on, voltage is supplied through IG2 fuse to other side of circuit opening relay. When proper input signals are delivered to Engine Control Module (ECM), circuit opening relay ground circuit is grounded at ECM terminal FC. Circuit opening relay then provides voltage to fuel pump for fuel pump operation. For circuit opening relay location, see CIRCUIT OPENING RELAY LOCATION table. Circuit opening relay may also be identified by appropriate illustration in appropriate SYSTEM & COMPONENT TESTING article.
Circuit Opening Relay (Camry Solara & Highlander)

Circuit opening relay controls fuel pump circuit. When EFI main relay is energized, it provides battery voltage to one side of circuit opening relay. When ignition is turned on, voltage is supplied through IGN fuse to other side of circuit opening relay. When proper input signals are delivered to Engine Control Module (ECM), circuit opening relay ground circuit is grounded at ECM terminal FC. Circuit opening relay then provides voltage to fuel pump for fuel pump operation. For circuit opening relay location, see CIRCUIT OPENING RELAY LOCATION table. Circuit opening relay may also be identified by appropriate illustration in appropriate SYSTEM & COMPONENT TESTING article.
Circuit Opening Relay (Celica, ECHO & Prius)

Circuit opening relay controls fuel pump circuit. When EFI main relay is energized, it provides battery voltage to both sides of circuit opening relay. When proper input signals are delivered to Engine Control Module (ECM), circuit opening relay ground circuit is grounded at ECM terminal FC. Circuit opening relay then provides voltage to fuel pump for fuel pump operation. For circuit opening relay location, see

2002 ENGINE PERFORMANCE Theory & Operation

CIRCUIT OPENING RELAY LOCATION table. Circuit opening relay may also be identified by appropriate illustration in appropriate SYSTEM & COMPONENT TESTING article.
Circuit Opening Relay (Corolla)

Circuit opening relay controls fuel pump circuit. When EFI main relay is energized, it provides battery voltage to both sides of circuit opening relay. EFI main relay may also be referred to as EFI relay or F-HTR relay. When proper input signals are delivered to Engine Control Module (ECM), circuit opening relay ground circuit is grounded at ECM terminal FC. Circuit opening relay then provides voltage to fuel pump for fuel pump operation. For circuit opening relay location, see CIRCUIT OPENING RELAY LOCATION table. Circuit opening relay may also be identified by appropriate illustration in appropriate SYSTEM & COMPONENT TESTING article.
Circuit Opening Relay (MR2)

Circuit opening relay controls fuel pump circuit. When EFI main relay is energized, it provides battery voltage to one side of circuit opening relay. When ignition is turned on, voltage is supplied from ignition switch to other side of circuit opening relay. When proper input signals are delivered to Engine Control Module (ECM), circuit opening relay ground circuit is grounded at ECM terminal FC. Circuit opening relay then provides voltage to fuel pump for fuel pump operation. For circuit opening relay location, see CIRCUIT OPENING RELAY LOCATION table. Circuit opening relay may also be identified by appropriate illustration in appropriate SYSTEM & COMPONENT TESTING article.
Circuit Opening Relay (RAV4)

Circuit opening relay controls fuel pump circuit. When EFI main relay is energized, it provides battery voltage to one side of circuit opening relay. When ignition is turned on, voltage is supplied to other side of circuit opening relay from IG2 fuse. When proper input signals are delivered to Engine Control Module (ECM), circuit opening relay ground circuit is grounded at ECM terminal FC. Circuit opening relay then provides voltage to fuel pump for fuel pump operation. For circuit opening relay location, see CIRCUIT OPENING RELAY LOCATION table. Circuit opening relay may also be identified by appropriate illustration in appropriate SYSTEM & COMPONENT TESTING article.
Circuit Opening Relay (Sequoia)

Circuit opening relay controls fuel pump circuit by supplying voltage to fuel pump relay. When EFI main relay is energized, it provides battery voltage to one side of circuit opening relay. When ignition is turned on, voltage is supplied through IGN1 fuse to other side of circuit opening relay. When proper input signals are delivered to Engine Control Module (ECM), circuit opening relay ground circuit is grounded at ECM terminal FC. Circuit opening relay then provides voltage to fuel pump relay which supplies voltage to fuel pump for fuel pump operation. For circuit opening relay location, see CIRCUIT OPENING RELAY LOCATION table. Circuit opening relay may also be identified by appropriate illustration in appropriate SYSTEM & COMPONENT TESTING article. For operation of fuel pump relay, see FUEL PUMP RELAY & FUEL PUMP RESISTOR (SEQUOIA & TUNDRA 4.7L V8) .
Circuit Opening Relay (Sienna & Tacoma)

Circuit opening relay controls fuel pump circuit. When EFI main relay is energized, it provides battery voltage to one side of circuit opening relay. When ignition is turned on, voltage is supplied through IGN fuse to other side of circuit opening relay. When proper input signals are delivered to Engine Control Module (ECM), circuit opening relay ground circuit is grounded at ECM terminal FC. Circuit opening relay then provides voltage to fuel pump for fuel pump operation. For circuit opening relay location, see

2002 ENGINE PERFORMANCE Theory & Operation

CIRCUIT OPENING RELAY LOCATION table. Circuit opening relay may also be identified by appropriate illustration in appropriate SYSTEM & COMPONENT TESTING article.
Circuit Opening Relay (Tundra 3.4L V6)

Circuit opening relay controls fuel pump circuit. When EFI main relay is energized, it provides battery voltage to both sides of circuit opening relay. When proper input signals are delivered to Engine Control Module (ECM), circuit opening relay ground circuit is grounded at ECM terminal FC. Circuit opening relay then provides voltage to fuel pump for fuel pump operation. For circuit opening relay location, see CIRCUIT OPENING RELAY LOCATION table. Circuit opening relay may also be identified by appropriate illustration in appropriate SYSTEM & COMPONENT TESTING article
Circuit Opening Relay (Tundra 4.7L V8)

Circuit opening relay controls fuel pump circuit by supplying voltage to fuel pump relay. When EFI main relay is energized, it provides battery voltage to one side of circuit opening relay. When ignition is turned on, voltage is supplied through IGN fuse to other side of circuit opening relay. When proper input signals are delivered to Engine Control Module (ECM), circuit opening relay ground circuit is grounded at ECM terminal FC. Circuit opening relay then provides voltage to fuel pump relay which supplies voltage for fuel pump operation. For circuit opening relay location, see CIRCUIT OPENING RELAY LOCATION table. Circuit opening relay may also be identified by appropriate illustration in appropriate SYSTEM & COMPONENT TESTING article. For operation of fuel pump relay, see FUEL PUMP RELAY & FUEL PUMP RESISTOR (SEQUOIA & TUNDRA 4.7L V8) .
Circuit Opening Relay (4Runner)

Circuit opening relay controls fuel pump circuit. When EFI main relay is energized, it provides battery voltage to one side of circuit opening relay. When ignition is turned on, voltage is supplied through IGN fuse to other side of circuit opening relay. When proper input signals are delivered to Engine Control Module (ECM), circuit opening relay ground circuit is grounded at ECM terminal FC. Circuit opening relay then provides voltage to fuel pump for fuel pump operation. For circuit opening relay location, see CIRCUIT OPENING RELAY LOCATION table. Circuit opening relay may also be identified by appropriate illustration in appropriate SYSTEM & COMPONENT TESTING article. CIRCUIT OPENING RELAY LOCATION (1) Application Location Avalon Top Corner Of Relay Box Behind Driver's Side Kick Panel Camry & Camry Solara In Fuse/Relay Box At Driver's Side Front Corner Of Engine Compartment Celica In Fuse/Relay Box At Driver's Side Front Corner Of Engine Compartment, Just In Front Of Strut Tower Corolla Center Relay In Relay Box Behind Driver's Side Kick Panel ECHO In Fuse/Relay Box Behind Driver's Side Of Instrument Panel Highlander In Relay Box Just Above Driver's Side Kick Panel MR2 In Relay Box On Firewall At Driver's Side Front Corner Of Engine Compartment Prius & RAV4 In Fuse/Relay Box At Driver's Side Front Corner Of Engine Compartment Sequoia & Sienna In Fuse/Relay Box At Driver's Side Front Corner Of Engine

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Compartment Tacoma Behind Lower Instrument Panel Cover, Next To Driver's Side Of Steering Column Tundra In Fuse/Relay Box At Driver's Side Front Corner Of Engine Compartment 4Runner Below Right Corner Of Fuse/Relay Box, Behind Lower Instrument Panel Cover At Driver's Side Of Instrument Panel To Left Of Steering Column, Just Above Hood Release Lever (1) Circuit opening relay may be marked as CIR OPN relay.
EFI Main Relay (Avalon)

EFI main relay may also be referred to as EFI relay. EFI No. 1 fuse supplies constant battery voltage to one side of EFI main relay. EFI main relay is energized by MREL terminal of Engine Control Module (ECM). When EFI main relay is energized, EFI main relay provides battery voltage to circuit opening relay, EFI No. 2 fuse, +B terminal of ECM and various other electrical components. For EFI main relay location, see EFI MAIN RELAY LOCATION table.
EFI Main Relay (Camry & Camry Solara)

EFI main relay may also be referred to as EFI relay. EFI fuse supplies constant battery voltage to one side of EFI main relay. EFI main relay is energized by MREL terminal of Engine Control Module (ECM). When EFI main relay is energized, EFI main relay provides battery voltage to circuit opening relay, +B terminal of ECM and various other electrical components. For EFI main relay location, see EFI MAIN RELAY LOCATION table.
EFI Main Relay (Celica)

EFI main relay may also be referred to as EFI relay. EFI fuse supplies constant battery voltage to one side of EFI main relay. EFI main relay is energized by MREL terminal of Engine Control Module (ECM). When EFI main relay is energized, EFI main relay provides battery voltage to circuit opening relay, +B terminal of ECM, EFI No. 1 and 2 fuses, and various other electrical components. For EFI main relay location, see EFI MAIN RELAY LOCATION table.
EFI Main Relay (Corolla)

EFI main relay may also be referred to as EFI relay or F-HTR relay. EFI fuse supplies constant battery voltage to one side of EFI main relay. EFI fuse may also be referred to as F-HTR fuse. When ignition is turned on, voltage is supplied through IGN fuse to other side of EFI main relay. EFI main relay is then energized and provides battery voltage to circuit opening relay, +B terminal of Engine Control Module (ECM) and various other electrical components. For EFI main relay location, see EFI MAIN RELAY LOCATION table.
EFI Main Relay (ECHO)

EFI main relay may also be referred to as EFI relay. EFI fuse supplies constant battery voltage to one side of EFI main relay. When ignition is turned on, voltage is supplied to other side of EFI main relay. EFI main relay is then energized and provides battery voltage to circuit opening relay, +B terminal of Engine Control Module (ECM) and various other electrical components. For EFI main relay location, see EFI MAIN RELAY LOCATION table.

2002 ENGINE PERFORMANCE Theory & Operation

EFI Main Relay (Highlander)

EFI main relay may also be referred to as EFI relay. EFI fuse supplies constant battery voltage to one side of EFI main relay. EFI main relay is energized by MREL terminal of Engine Control Module (ECM). When EFI main relay is energized, EFI main relay provides battery voltage to circuit opening relay, +B terminal of ECM and various other electrical components. For EFI main relay location, see EFI MAIN RELAY LOCATION table.
EFI Main Relay (Land Cruiser)

EFI main relay may also be referred to as EFI relay or ECD relay. EFI fuse supplies constant battery voltage to one side of EFI main relay. EFI fuse may also be referred to as ECD fuse. EFI main relay is energized by MREL terminal of Engine Control Module (ECM). When EFI main relay is energized, EFI main relay provides battery voltage to +B terminal of fuel pump Electronic Control Unit (ECU), +B and +B1 terminals of ECM and various other electrical components. For operation of fuel pump ECU and fuel pump switch, see FUEL PUMP ELECTRONIC CONTROL UNIT & FUEL PUMP SWITCH (LAND CRUISER) . For EFI main relay location, see EFI MAIN RELAY LOCATION table.
EFI Main Relay (MR2)

EFI main relay may also be referred to as EFI relay. EFI No. 1 fuse supplies constant battery voltage to one side of EFI main relay. EFI main relay is energized by MREL terminal of Engine Control Module (ECM). When EFI main relay is energized, EFI main relay provides battery voltage to circuit opening relay, +B terminal of ECM and various other electrical components. For EFI main relay location, see EFI MAIN RELAY LOCATION table.
EFI Main Relay (Prius)

EFI main relay may also be referred to as EFI relay. EFI fuse supplies constant battery voltage to one side of EFI main relay. EFI main relay is energized by MREL terminal of Engine Control Module (ECM). When EFI main relay is energized, EFI main relay provides battery voltage to circuit opening relay, +B terminal of ECM and various other electrical components. For EFI main relay location, see EFI MAIN RELAY LOCATION table.
EFI Main Relay (RAV4)

EFI main relay may also be referred to as EFI relay. EFI No. 2 fuse supplies constant battery voltage to one side of EFI main relay. EFI main relay is energized by MREL terminal of Engine Control Module (ECM). When EFI main relay is energized, EFI main relay provides battery voltage to circuit opening relay, A/F heater relay, +B terminal of ECM and various other electrical components. For EFI main relay location, see EFI MAIN RELAY LOCATION table.
EFI Main Relay (Sequoia)

EFI main relay may also be referred to as EFI relay. EFI No. 1 fuse supplies constant battery voltage to one side of EFI main relay. EFI main relay is energized by MREL terminal of Engine Control Module (ECM). When EFI main relay is energized, EFI main relay provides battery voltage to +B and +B1 terminals of ECM, circuit opening relay, EFI No. 2 fuse and various other electrical components. For EFI main relay location, see EFI MAIN RELAY LOCATION table.
EFI Main Relay (Sienna)

2002 ENGINE PERFORMANCE Theory & Operation

EFI main relay may also be referred to as EFI relay. EFI fuse supplies constant battery voltage to one side of EFI main relay. EFI main relay is energized by MREL terminal of Engine Control Module (ECM). When EFI main relay is energized, EFI main relay provides battery voltage to circuit opening relay, +B terminal of ECM and various other electrical components. For EFI main relay location, see EFI MAIN RELAY LOCATION table.
EFI Main Relay (Tacoma 2.4L 4-Cyl. & 2.7L 4-Cyl.)

EFI main relay may also be referred to as EFI relay. EFI fuse supplies constant battery voltage to one side of EFI main relay. When ignition is turned on, voltage is supplied through IGN fuse to other side of EFI main relay. EFI main relay is then energized and provides battery voltage to circuit opening relay, +B terminal of Engine Control Module (ECM) and various other electrical components. For EFI main relay location, see EFI MAIN RELAY LOCATION table.
EFI Main Relay (Tacoma 3.4L V6)

EFI main relay may also be referred to as EFI relay. EFI fuse supplies constant battery voltage to one side of EFI main relay. EFI main relay is energized by MREL terminal of Engine Control Module (ECM). When EFI main relay is energized, EFI main relay provides battery voltage to circuit opening relay, +B terminal of ECM and various other electrical components. For EFI main relay location, see EFI MAIN RELAY LOCATION table.
EFI Main Relay (Tundra 3.4L V6)

EFI main relay may also be referred to as EFI relay. EFI No. 1 fuse supplies constant battery voltage to one side of EFI main relay. EFI main relay is energized by MREL terminal of Engine Control Module (ECM). When EFI main relay is energized, EFI main relay provides battery voltage to circuit opening relay, +B terminal of ECM and various other electrical components. For EFI main relay location, see EFI MAIN RELAY LOCATION table.
EFI Main Relay (Tundra 4.7L V8)

EFI main relay may also be referred to as EFI relay. EFI fuse No. 1 supplies constant battery voltage to one side of EFI main relay. EFI main relay is energized by MREL terminal of Engine Control Module (ECM). When EFI main relay is energized, EFI main relay provides battery voltage to circuit opening relay, +B and +B1 terminals of ECM, EFI fuse No. 2 and various other electrical components. For EFI main relay location, see EFI MAIN RELAY LOCATION table.
EFI Main Relay (4Runner)

EFI main relay may also be referred to as EFI relay. EFI fuse supplies constant battery voltage to one side of EFI main relay. EFI main relay is energized by MREL terminal of Engine Control Module (ECM). When EFI main relay is energized, EFI main relay provides battery voltage to circuit opening relay, +B terminal of ECM and various other electrical components. For EFI main relay location, see EFI MAIN RELAY LOCATION table. EFI MAIN RELAY LOCATION Application Avalon, Camry & Camry Solara Celica, Corolla, ECHO & Highlander

Location In Fuse/Relay Box At Driver's Side Front Corner Of Engine Compartment In Fuse/Relay Box At Driver's Side Front Corner Of Engine

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Compartment, Just In Front Of Strut Tower Land Cruiser In Fuse/Relay Box At Driver's Side Front Corner Of Engine Compartment MR2 In Relay Box On Firewall At Driver's Side Front Corner Of Engine Compartment Prius, RAV4, Sequoia, Sienna, Tacoma, In Fuse/Relay Box At Driver's Side Front Corner Of Engine Tundra & 4Runner Compartment
Fuel Pump (Avalon, Camry, Camry Solara, Celica, Corolla, ECHO, Highlander, MR2, Prius, RAV4, Sienna, Tacoma, Tundra 3.4L V6 & 4Runner)

Electric fuel pump is mounted in fuel tank. Fuel pump operates at one specified speed.
Fuel Pump (Land Cruiser)

Electric fuel pump is mounted in fuel tank. Fuel pump operating speed is varied by use of fuel pump Electronic Control Unit (ECU). For additional information, see FUEL PUMP ELECTRONIC CONTROL UNIT & FUEL PUMP SWITCH (LAND CRUISER) .
Fuel Pump (Sequoia & Tundra 4.7L V8)

Electric fuel pump is mounted in fuel tank. Fuel pump operating speed is controlled by operating condition of the engine such as: starting, idling, light load or heavy load. This is accomplished by use of fuel pump resistor and fuel pump relay. For operation of fuel pump relay and fuel pump resistor, see FUEL PUMP RELAY & FUEL PUMP RESISTOR (SEQUOIA & TUNDRA 4.7L V8) .
Fuel Pump Electronic Control Unit & Fuel Pump Switch (Land Cruiser)

Fuel pump operating speed is controlled by engine operating conditions such as: starting, idling, light load or heavy load. Engine Control Module (ECM) delivers an input signal from FPC terminal on ECM to FPC terminal on fuel pump Electronic Control Unit (ECU) in accordance with engine operating condition. Fuel pump ECU uses this input signal to determine how much voltage should be delivered to fuel pump for varying fuel pump operating speed. When engine starts, or engine is under heavy load at high speeds, ECM delivers input signal of approximately 3.8 volts to fuel pump ECU. Fuel pump ECU then delivers approximately battery voltage to fuel pump and fuel pump operates at high speed. When engine is under heavy load at low speeds, ECM delivers an input signal of approximately 2.5 volts to fuel pump ECU. Fuel pump ECU then delivers approximately 10 volts to fuel pump and fuel pump operates at medium speed. When engine is idling or under light loads, ECM delivers an input signal of approximately 1.3 volts to fuel pump ECU. Fuel pump ECU then delivers approximately 8.5 volts to fuel pump and fuel pump operates at low speed. If a problem exists in fuel pump ECU or control circuit, Diagnostic Trouble Code (DTC) P1200 may be stored in ECM. See TESTING PROCEDURE under SELF-DIAGNOSTIC SYSTEM in appropriate SELF-DIAGNOSTICS article for retrieval of DTCs. Fuel pump ECU is located behind inner panel, just behind driver's rear wheelwell. See Fig. 55 . Fuel pump switch is in the circuit between FPC terminal on ECM and FPC terminal on fuel pump ECU. Fuel pump switch may also be referred to as fuel pump inertia switch or fuel pump control switch. If vehicle is involved in a collision, fuel pump switch will shut off the fuel pump by opening this circuit, and not allowing any input signal to be delivered from ECM to fuel pump ECU. Fuel pump switch is located on driver's side of instrument panel. See Fig. 56 . Fuel pump switch contains a reset switch which has an OFF and ON position. See Fig. 56 . Continuity will exist between electrical terminals on fuel pump switch with reset switch in the ON position and no continuity in the OFF position. Reset switch must be in ON position

2002 ENGINE PERFORMANCE Theory & Operation

Fig. 56: Locating Fuel Pump Switch & Identifying Reset Switch Positions (Land Cruiser) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Fuel Pump Relay & Fuel Pump Resistor (Sequoia & Tundra 4.7L V8)

Fuel pump operating speed is controlled by operating condition of the engine such as; starting, idling, light load or heavy load. When engine is cranking and start signal is received at Engine Control Module (ECM), the ECM energizes circuit opening relay and voltage is applied to both sides of fuel pump relay. Fuel pump relay contacts are closed on one side and voltage is applied directly to fuel pump in which fuel pump operates at high speed. After engine starts during idling or light loads, fuel pump relay is energized by FPR terminal of ECM and contacts in fuel pump relay close to other side of relay. Voltage is then supplied to fuel pump by going from fuel pump relay through fuel pump resistor. Fuel pump now operates at low speed. Fuel pump relay is located in fuse/relay box at driver's side front corner of engine compartment. Fuel pump

2002 ENGINE PERFORMANCE Theory & Operation

resistor is located at driver's side front corner of engine compartment, near end of fuse/relay box. See Fig. 57 .

Fig. 57: Locating Fuel Pump Resistor (Sequoia & Tundra 4.7L V8) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Fuel Pressure Regulator (Avalon, Camry, Camry Solara, Celica, Corolla, ECHO, Highlander, MR2, Prius, RAV4 & Sienna)

Fuel system is a returnless type system with fuel pressure regulator mounted on fuel pump in the fuel tank. Fuel pressure regulator maintains constant fuel pressure to the fuel injectors.
Fuel Pressure Regulator (Land Cruiser, Sequoia, Tacoma & Tundra)

Fuel pressure regulator is mounted on the fuel rail and maintains constant fuel pressure to fuel injectors.
IG2 Relay (Avalon, Celica, MR2, Prius & RAV4)

See IG2 RELAY under MISCELLANEOUS CONTROLS. FUEL CONTROL

Fuel Cut System (All Models)

Controlled through input signals, Engine Control Module (ECM) will shut off fuel delivery momentarily

2002 ENGINE PERFORMANCE Theory & Operation

during closed throttle deceleration.

Fuel Injectors

Fuel injectors are electrically operated solenoids which deliver fuel to individual cylinders. Engine Control Module (ECM) controls fuel injector duration based on various input signals to determine air/fuel mixture. IDLE SPEED
A/C-Cut Control System (Corolla, Highlander, MR2, Prius & RAV4)

Engine Control Module (ECM) uses various input signals for controlling A/C-cut control system. A/C-cut control system interrupts A/C compressor operation for a fixed period of time when vehicle accelerates from low engine speed.
Dashpot (Tacoma 3.4L V6 With M/T)

Dashpot is mounted on throttle body and is used to allow engine to slowly return to specified RPM after throttle is released.
Idle Speed Control System (Avalon, Camry Solara 3.0L V6, Celica, Corolla, ECHO, Highlander, MR2 With Standard Type Manual Transaxle, RAV4, Sienna, Tacoma & Tundra 3.4L V6)

Idle speed control system may also be referred to as idle air control system. Engine Control Module (ECM) is programmed with engine idle speed values. Idle speed control system provides a stable idle speed when engine is cold, or idle speed decreases due to electrical load etc. ECM uses various input signals to maintain proper idle speed by controlling Idle Air Control (IAC) valve.
Throttle Control Motor (Camry, Camry Solara 2.4L 4-Cyl., Land Cruiser, Prius, Sequoia, Tundra 4.7L V8 & 4Runner)

Throttle control motor is used with Electronic Throttle Control System (ETCS) for controlling throttle operation and idle speed. See ELECTRONIC THROTTLE CONTROL SYSTEM under AIR INDUCTION SYSTEMS for additional information.
Throttle Control Motor (MR2 With Sequential Manual Transaxle)

There are 2 types of manual transaxles used for this model. Standard type manual transaxle in which the driver operates the clutch and shifts the transaxle, and the sequential manual transaxle, which is electronically controlled and the clutch is operated and transaxle is shifted hydraulically by moving the shift lever forward or backward. Sequential manual transaxle may be identified by the shift lever pattern which consists of "R", "N", "S" and "+" in place of the conventional type shift lever pattern and there is no clutch pedal. Models with sequential manual transaxle use throttle control motor with Electronic Throttle Control System (ETCS) for controlling throttle operation and idle speed. See ELECTRONIC THROTTLE CONTROL SYSTEM under AIR INDUCTION SYSTEMS for additional information.
Throttle Opener (Avalon, Camry Solara 3.0L V6, Sienna, Tacoma & Tundra 3.4L V6)

Throttle opener, mounted on throttle body, is vacuum controlled and allows engine to return to specified RPM after throttle is released.

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IGNITION SYSTEMS
DISTRIBUTORLESS IGNITION SYSTEM NOTE: Distributorless ignition system may also be referred to as Electronic Spark Advance (ESA) system.

Avalon, Highlander 3.0L V6 & Sienna

Distributorless Ignition System (DIS) uses Engine Control Module (ECM) for determining ignition timing (spark advance). ECM may determine ignition timing (spark advance) based on various input signals, engine RPM and knock sensor input signals. Conventional distributor and pick-up coil have been replaced by 2 camshaft position sensors and crankshaft position sensor. Camshaft position sensors may also be referred to as Variable Valve Timing (VVT) sensors. Camshaft position sensors and crankshaft position sensor deliver input signals to ECM. ECM detects standard crankshaft position based on input signals from camshaft position sensors and actual crankshaft position, and engine speed by crankshaft position sensor input signals. Camshaft position sensors are located at flywheel end of each cylinder head, just below valve cover. See Fig. 13 , Fig. 22 and Fig. 28 . Crankshaft position sensor is located at front of crankshaft, near crankshaft pulley. See Fig. 13 , Fig. 22 and Fig. 28 . For knock sensor location, see KNOCK SENSOR under ENGINE SENSORS & SWITCHES in REMOVAL, OVERHAUL & INSTALLATION - V6 & V8 article. The ECM uses 6 ignition primary control signals to the ignitors for the ignition coils. DIS uses 6 ignition coils with internal ignitors, one ignition coil for each cylinder. See Fig. 58 . Cylinder No. 1 is front cylinder on right side of engine when viewed from flywheel end of engine. Cylinder No. 2 is front cylinder on left side of engine when viewed from flywheel end of engine. Cylinders No. 1, 3 and 5 are on right side of engine. Cylinders No. 2, 4 and 6 are on left side of engine. ECM monitors IGF circuit at ignitor to ensure ignition coils have fired. NOTE: On Avalon, IG2 relay provides voltage to ignition coils. For additional information on IG2 relay, see IG2 RELAY under MISCELLANEOUS CONTROLS.

2002 ENGINE PERFORMANCE Theory & Operation

Fig. 58: Distributorless Ignition System Schematic (Avalon, Highlander 3.0L V6 & Sienna) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Camry 2.4L 4-Cyl., Camry Solara 2.4L 4-Cyl., Celica, Corolla, ECHO, Highlander 2.4L 4-Cyl., MR2, Prius & RAV4

Distributorless Ignition System (DIS) uses Engine Control Module (ECM) for determining ignition timing (spark advance). ECM may determine ignition timing (spark advance) based on various input signals, engine RPM and knock sensor input signal. Conventional distributor and pick-up coil have been replaced by camshaft position sensor and crankshaft position sensor. Camshaft position sensor may also be referred to as Variable Valve Timing (VVT) sensor. Camshaft position sensor and crankshaft position sensor deliver input signals to ECM. ECM detects standard crankshaft position based on camshaft position sensor input signals and actual crankshaft position, and engine speed by crankshaft position sensor input signals. On Camry, Camry Solara, ECHO, Highlander, Prius and RAV4, camshaft position sensor is located on end of cylinder head at flywheel end of engine. See Fig. 14 , Fig. 16 , Fig. 20 , Fig. 21 , Fig. 25 and Fig. 26 . On Celica, Corolla and MR2, camshaft position sensor is located just above intake manifold on cylinder head, at flywheel end of engine. See Fig. 18 , Fig. 19 and Fig. 24 . On all models, crankshaft position sensor is located on front of engine, near crankshaft pulley. See Fig. 14 -Fig. 26 . For knock sensor location, see KNOCK SENSOR under ENGINE SENSORS & SWITCHES in REMOVAL, OVERHAUL & INSTALLATION - 4-CYLINDER article. ECM uses 4 ignition primary control signals to ignitors for ignition coils. DIS uses 4 ignition coils with internal ignitors, one ignition coil for each cylinder. See Fig. 59 . Cylinder No. 1 is front cylinder at timing chain end of engine and cylinder No. 4 is rear cylinder at flywheel end of engine. ECM monitors IGF circuit at ignitor to ensure ignition coils have fired.

2002 ENGINE PERFORMANCE Theory & Operation

NOTE:

On Celica, MR2, Prius and RAV4, IG2 relay provides voltage to ignition coils. For additional information on IG2 relay, see IG2 RELAY under MISCELLANEOUS CONTROLS.

Fig. 59: Typical Distributorless Ignition System Schematic (Camry 2.4L 4-Cyl., Camry Solara 2.4L 4Cyl., Celica, Corolla, ECHO, Highlander 2.4L 4-Cyl., MR2, Prius, RAV4 & Tacoma 2.4L 4-Cyl. & 2.7L 4-Cyl.) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Camry 3.0L V6

Distributorless Ignition System (DIS) uses Engine Control Module (ECM) for determining ignition timing (spark advance). ECM may determine ignition timing (spark advance) based on various input signals, engine RPM and knock sensor input signals. Conventional distributor and pick-up coil have been replaced by camshaft position sensor and crankshaft position sensor. Camshaft position sensor and crankshaft position sensor deliver input signals to ECM. ECM detects standard crankshaft position based on input signals from camshaft position sensor and actual crankshaft position, and engine speed by crankshaft position sensor input signals. Camshaft position sensor is located at flywheel end of front (radiator side) cylinder head, just below valve cover. See Fig. 15 . Crankshaft position sensor is located at front of crankshaft, near crankshaft pulley. See Fig. 15 . For knock sensor location, see KNOCK SENSOR under ENGINE SENSORS & SWITCHES in REMOVAL, OVERHAUL & INSTALLATION - V6 & V8 article. The ECM uses 6 ignition primary control signals to the ignitors for the ignition coils. DIS uses 6 ignition coils with internal ignitors, one ignition coil for each cylinder. See Fig. 60 . Cylinder No. 1 is front cylinder on right side of engine when viewed from flywheel end of engine. Cylinder No. 2 is front cylinder on left side of engine when viewed from flywheel end of engine. Cylinders No. 1, 3 and 5 are on right side of

2002 ENGINE PERFORMANCE Theory & Operation

engine. Cylinders No. 2, 4 and 6 are on left side of engine. ECM monitors IGF circuit at ignitor to ensure ignition coils have fired.

Fig. 60: Distributorless Ignition System Schematic (Camry 3.0L V6) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Camry Solara 3.0L V6

Distributorless Ignition System (DIS) uses Engine Control Module (ECM) for determining ignition timing (spark advance). ECM may determine ignition timing (spark advance) based on various input signals, engine RPM and knock sensor input signals. Conventional distributor and pick-up coil have been replaced by camshaft position sensor and crankshaft position sensor. Camshaft position sensor and crankshaft position sensor deliver input signals to ECM. ECM detects standard crankshaft position based on camshaft position sensor input signals and actual crankshaft position, and engine speed by crankshaft position sensor input signals. Camshaft position sensor is located at flywheel end of front (radiator side) cylinder head, just below valve cover. See Fig. 17 . Crankshaft position sensor is located at front of crankshaft, near crankshaft pulley. See Fig. 17 . For knock sensor location, see KNOCK SENSOR under ENGINE SENSORS & SWITCHES in REMOVAL, OVERHAUL & INSTALLATION - V6 & V8 article. ECM uses 3 ignition primary control signals to ignitor for ignition coils. DIS uses 3 ignition coils which fire 2 cylinders simultaneously using same ignition coil. See Fig. 61 . Cylinder No. 1 is front cylinder on right side of engine when viewed from flywheel end of engine. Cylinder No. 2 is front cylinder on left side of engine when viewed from flywheel end of engine. Cylinders No. 1, 3 and 5 are on right side of engine. Cylinders No. 2, 4 and 6 are on left side of engine.

2002 ENGINE PERFORMANCE Theory & Operation

One ignition coil is mounted on top of spark plug on cylinders No. 2, 4 and 6. Spark plug wires are routed from ignition coils on top of spark plugs to spark plugs on remaining cylinders. ECM monitors IGF circuit at ignitor to ensure ignition coils have fired.

Fig. 61: Distributorless Ignition System Schematic (Camry Solara 3.0L V6) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Land Cruiser, Sequoia & Tundra 4.7L V8

Distributorless Ignition System (DIS) uses Engine Control Module (ECM) for determining ignition timing (spark advance). ECM may determine ignition timing (spark advance) based on various input signals, engine RPM and knock sensor input signals. Conventional distributor and pick-up coil have been replaced by camshaft position sensor and crankshaft position sensor. Camshaft position sensor and crankshaft position sensor deliver input signals to ECM. ECM detects standard crankshaft position based on camshaft position sensor input signals and actual crankshaft position, and engine speed by crankshaft position sensor input signals. Camshaft position sensor is located behind driver's side upper timing belt cover, near camshaft sprocket. See Fig. 23 , Fig. 27 and Fig. 32 . Crankshaft position sensor is located at front of crankshaft, near crankshaft pulley. See Fig. 23 , Fig. 27 and Fig. 32 . For knock sensor location, see KNOCK SENSOR under ENGINE SENSORS & SWITCHES in REMOVAL, OVERHAUL & INSTALLATION - V6 & V8 article. The ECM uses 8 ignition primary control signals to ignitors for ignition coils. DIS uses 8 ignition coils with internal ignitors, one ignition coil for each cylinder. See Fig. 62 . Cylinder No. 1 is front cylinder on left

2002 ENGINE PERFORMANCE Theory & Operation

side of engine when viewed from flywheel end of engine. Cylinder No. 2 is front cylinder on right side of engine when viewed from flywheel end of engine. Cylinders No. 1, 3, 5 and 7 are on left side of engine. Cylinders No. 2, 4, 6 and 8 are on right side of engine. The ECM monitors IGF circuit at ignitor to ensure ignition coils have fired.

Fig. 62: Distributorless Ignition System Schematic (Land Cruiser, Sequoia & Tundra 4.7L V8) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Tacoma 2.4L 4-Cyl. & 2.7L 4-Cyl.

Distributorless Ignition System (DIS) uses Engine Control Module (ECM) for determining ignition timing (spark advance). ECM may determine ignition timing (spark advance) based on various input signals, engine RPM and knock sensor input signal.

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Conventional distributor and pick-up coil have been replaced by camshaft position sensor and crankshaft position sensor. Camshaft position sensor and crankshaft position sensor deliver input signals to ECM. ECM detects standard crankshaft position based on camshaft position sensor input signals and actual crankshaft position, and engine speed by crankshaft position sensor input signals. Camshaft position sensor is located at driver's side front corner of cylinder head, just in front of intake manifold. See Fig. 29 . Crankshaft position sensor is located near crankshaft pulley, just above oil pan on driver's side of engine. See Fig. 29 . For knock sensor location, see KNOCK SENSOR under ENGINE SENSORS & SWITCHES in REMOVAL, OVERHAUL & INSTALLATION - 4-CYLINDER article. ECM uses 4 ignition primary control signals to ignitors for ignition coils. DIS uses 4 ignition coils with internal ignitors, one ignition coil for each cylinder. See Fig. 59 . Cylinder No. 1 is front cylinder at timing chain end of engine and cylinder No. 4 is rear cylinder at flywheel end of engine. ECM monitors IGF circuit at ignitor to ensure ignition coils have fired.
Tacoma 3.4L V6, Tundra 3.4L V6 & 4Runner

Distributorless Ignition System (DIS) uses Engine Control Module (ECM) for determining ignition timing (spark advance). ECM may determine ignition timing (spark advance) based on various input signals, engine RPM and knock sensor input signals. Conventional distributor and pick-up coil have been replaced by camshaft position sensor and crankshaft position sensor. Camshaft position sensor and crankshaft position sensor deliver input signals to ECM. ECM detects standard crankshaft position based on camshaft position sensor input signals and actual crankshaft position, and engine speed by crankshaft position sensor input signals. Camshaft position sensor is located behind upper timing belt cover, near passenger's side camshaft sprocket. See Fig. 30 , Fig. 31 and Fig. 33 . Crankshaft position sensor is located at front of engine, just above crankshaft pulley. See Fig. 30 , Fig. 31 and Fig. 33 . For knock sensor location, see KNOCK SENSOR under ENGINE SENSORS & SWITCHES in REMOVAL, OVERHAUL & INSTALLATION - V6 & V8 article. ECM uses 3 ignition primary control signals to ignitor for ignition coils. See Fig. 63 . DIS uses 3 ignition coils which fire 2 cylinders simultaneously using same ignition coil. Cylinders No. 1 and 4 fire together, 2 and 5 fire together, and 3 and 6 fire together. Cylinder No. 1 is front cylinder on right side of engine when viewed from flywheel end of engine. Cylinder No. 2 is front cylinder on left side of engine when viewed from flywheel end of engine. Cylinders No. 1, 3 and 5 are on right side of engine. Cylinders No. 2, 4 and 6 are on left side of engine. One ignition coil is mounted on top of spark plug on cylinder No. 1 with spark plug wire going to cylinder No. 4 spark plug. One ignition coil is mounted on top of spark plug on cylinder No. 3 with spark plug wire going to cylinder No. 6 spark plug. One ignition coil is mounted on top of spark plug on cylinder No. 5 with spark plug wire going to cylinder No. 2 spark plug. ECM monitors IGF circuit at ignitor to ensure ignition coils have fired.

2002 ENGINE PERFORMANCE Theory & Operation

Fig. 63: Distributorless Ignition System Schematic (Tacoma 3.4L V6, Tundra 3.4L V6 & 4Runner) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

EMISSION SYSTEMS & SUB-SYSTEMS

EXHAUST GAS RECIRCULATION CONTROL
Camry 3.0L V6 & Camry Solara 3.0L V6

Exhaust Gas Recirculation (EGR) system reduces oxides of nitrogen (NOx) emissions by lowering combustion temperatures. Combustion temperatures are lowered by recycling metered amount of exhaust gases back into intake system. EGR system contains a vacuum-operated EGR valve, EGR position sensor, EGR Vacuum Switching Valve (VSV) EGR Vacuum Control Valve (VCV) and EGR gas temperature sensor which is screwed into lower side of EGR valve. See Fig. 64 . Amount of EGR operation is regulated by EGR VSV which is controlled by Engine Control Module (ECM). EGR position sensor monitors movement of EGR valve and delivers an input signal to the ECM. The ECM uses this input signal to obtain the correct amount of EGR valve opening in relation to engine operation. ECM may shut off EGR system if any of the following conditions exist:

2002 ENGINE PERFORMANCE Theory & Operation

Engine Is Not At Normal Operating Temperature During Deceleration With Throttle Closed During Light Engine Load Engine Is Idling Engine Speed Is Greater Than 4000 RPM

The ECM uses various input signals for controlling EGR system operation. For EGR system and component testing, see EXHAUST GAS RECIRCULATION SYSTEM under EMISSION SYSTEMS & SUBSYSTEMS in SYSTEM & COMPONENT TESTING - V6 & V8 article.

Fig. 64: Identifying EGR System Components (Camry 3.0L V6 & Camry Solara 3.0L V6) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Tacoma 2.7L 4-Cyl. 3RZ-FE

Exhaust Gas Recirculation (EGR) system reduces oxides of nitrogen (NOx) emissions by lowering combustion temperatures. Combustion temperatures are lowered by recycling metered amount of exhaust

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gases back into intake system. EGR system contains a vacuum-operated EGR valve, EGR vacuum modulator and EGR Vacuum Switching Valve (VSV). See Fig. 65 . Amount of EGR operation is regulated by EGR vacuum modulator according to engine load. EGR valve operation is controlled by EGR VSV which is controlled by Engine Control Module (ECM). If ECM turns on EGR VSV, this causes EGR valve to close and shut off the exhaust gas. ECM may shut off EGR system if any of the following conditions exist:

Engine Is Not At Normal Operating Temperature During Deceleration With Throttle Closed During Light Engine Load Engine Is At High Speed

The ECM uses various input signals for controlling EGR system operation. For EGR system and component testing, see EXHAUST GAS RECIRCULATION SYSTEM under EMISSION SYSTEMS & SUBSYSTEMS in SYSTEM & COMPONENT TESTING - 4-CYLINDER article.

Fig. 65: Identifying EGR System Components (Tacoma 2.7L 4-Cyl. 3RZ-FE) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. HYDROCARBON ADSORBER CATALYST SYSTEM
Prius

Hydrocarbon Adsorber Catalyst (HCAC) system is used to improve emissions when three-way catalytic converter temperature is low. HCAC system consists of HCAC Vacuum Switching Valve (VSV), actuator, by-pass valve and Three-Way Catalytic Converter (TWC) with Hydrocarbon (HC) adsorber. Actuator and

2002 ENGINE PERFORMANCE Theory & Operation

by-pass valve are located at front of TWC on exhaust pipe. See Fig. 66 . HCAC VSV is located on bracket bolted to timing chain end of engine and uses a Brown electrical connector with Black and Black/White wires. See Fig. 67 . Before engine is started, by-pass valve is open. When engine starts, Engine Control Module (ECM) delivers an output signal to HCAC VSV. HCAC VSV opens, allowing vacuum to be applied to actuator which causes the by-pass valve to close. When by-pass valve closes, exhaust gases pass into the HC adsorber, where the gases are stored until the temperature of front TWC increases. This prevents hydrocarbons from being delivered from vehicle when TWC temperature is low. After TWC becomes warm, the HCAC VSV closes and vacuum to by-pass valve is shut off, causing by-pass valve to open. When rear TWC becomes warm, exhaust emissions are cleaned by the TWC. The HCAC VSV may also be operated during a deceleration condition when HC adsorber is warm in order to scavenge the hydrocarbons that remain in the HC adsorber.

Fig. 66: Locating Actuator, By-Pass Valve & HC Adsorber (Prius) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

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Avalon, Camry, Camry Solara, Celica, Corolla, Highlander, MR2, RAV4, Sequoia, Sienna, Tacoma & 4Runner

EVAP system prevents fuel tank gasoline vapors from escaping into the atmosphere. Fuel tank gasoline vapors are routed through EVAP canister, then into air cleaner and intake manifold for combustion in the cylinders. Vapor pressure sensor, pressure switching valve Vacuum Switching Valve (VSV) and canister closed valve Vacuum Switching Valve (VSV) are used to determine if a leak or an abnormality exists in EVAP system. See Fig. 51 . Engine Control Module (ECM) determines if a leak or an abnormality exists in EVAP system by using input signal from vapor pressure sensor. Vapor pressure sensor may also be referred to as EVAP vapor pressure sensor. Canister closed valve VSV may also be referred to as EVAP Canister Closed Valve Vacuum Switching Valve (EVAP-CCVVSV). Pressure switching valve VSV may also be referred to as EVAP Pressure Switching Valve Vacuum Switching Valve (EVAP-PSVVSV). EVAP canister may also be referred to as charcoal canister. If a leak or an abnormality exists in EVAP system, a Diagnostic Trouble Code (DTC) will be stored in ECM. See TESTING PROCEDURE under SELF-DIAGNOSTIC SYSTEM in appropriate SELF-DIAGNOSTICS article for retrieval of DTCs. EVAP Vacuum Switching Valve (VSV) is used to control EVAP system. ECM operates EVAP VSV which controls vacuum flow for EVAP operation. For EVAP system and component testing, see FUEL EVAPORATIVE SYSTEM under EMISSION SYSTEMS & SUB-SYSTEMS in appropriate SYSTEM & COMPONENT TESTING article.
ECHO

EVAP system prevents fuel tank gasoline vapors from escaping into the atmosphere. Fuel tank gasoline vapors are routed through EVAP canister, then into air cleaner and intake manifold for combustion in the cylinders. Vapor pressure sensor and canister closed valve Vacuum Switching Valve (VSV) are used to determine if a leak or an abnormality exists in EVAP system. See Fig. 51 . Engine Control Module (ECM) determines if a leak or an abnormality exists in EVAP system by using input signal from vapor pressure sensor. Vapor pressure sensor may also be referred to as EVAP vapor pressure sensor. Canister closed valve VSV may also be referred to as EVAP Canister Closed Valve Vacuum Switching Valve (EVAP-CCVVSV). EVAP canister may also be referred to as charcoal canister. If a leak or an abnormality exists in EVAP system, a Diagnostic Trouble Code (DTC) will be stored in ECM. See TESTING PROCEDURE under SELF-DIAGNOSTIC SYSTEM in appropriate SELF-DIAGNOSTICS article for retrieving of DTCs. EVAP Vacuum Switching Valve (VSV) is used to control EVAP system. ECM operates EVAP VSV which controls vacuum flow for EVAP operation. For EVAP system and component testing, see FUEL EVAPORATIVE SYSTEM under EMISSION SYSTEMS & SUB-SYSTEMS in appropriate SYSTEM & COMPONENT TESTING article.
Land Cruiser & Tundra

EVAP system prevents fuel tank gasoline vapors from escaping into the atmosphere. Fuel tank gasoline vapors are routed through EVAP canister, then into air cleaner and intake manifold for combustion in the cylinders. Vapor pressure sensor and vapor pressure sensor Vacuum Switching Valve (VSV) are used to determine if a leak or an abnormality exists in EVAP system. See Fig. 52 . Engine Control Module (ECM) determines if a leak or an abnormality exists in EVAP system by using input signal from vapor pressure sensor. Vapor pressure sensor may also be referred to as EVAP vapor pressure sensor. Vapor pressure sensor VSV may also be referred to as EVAP Vapor Pressure Sensor Vacuum Switching Valve (EVAPVPSVSV). EVAP canister may also be referred to as charcoal canister. If a leak or an abnormality exists in EVAP system, a Diagnostic Trouble Code (DTC) will be stored in ECM. See TESTING PROCEDURE under SELF-DIAGNOSTIC SYSTEM in appropriate SELF-DIAGNOSTICS article for retrieval of DTCs. EVAP Vacuum Switching Valve (VSV) is used to control EVAP system. ECM operates EVAP VSV which controls vacuum flow for EVAP operation. For EVAP system and component testing, see FUEL EVAPORATIVE SYSTEM under EMISSION SYSTEMS & SUB-SYSTEMS in appropriate SYSTEM & COMPONENT TESTING article.

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Prius

EVAP system prevents fuel tank gasoline vapors from escaping into the atmosphere. Fuel tank gasoline vapors are routed through EVAP canister, then into air cleaner and intake manifold for combustion in the cylinders. Vapor pressure sensor, purge flow switching valve Vacuum Switching Valve (VSV) and canister closed valve Vacuum Switching Valve (VSV) are used to determine if a leak or an abnormality exists in the EVAP system. See Fig. 53 . Engine Control Module (ECM) determines if a leak or an abnormality exists in EVAP system by using input signal from vapor pressure sensor. Vapor pressure sensor may also be referred to as EVAP vapor pressure sensor. Canister closed valve VSV may also be referred to as EVAP Canister Closed Valve Vacuum Switching Valve (EVAP-CCVVSV) or Canister Closed Valve Vacuum Switching Valve (CCV VSV). Purge flow switching valve VSV may also be referred to as EVAP Purge Flow Switching Valve Vacuum Switching Valve (EVAP-PFSVVSV). EVAP canister may also be referred to as charcoal canister. If a leak or an abnormality exists in EVAP system, a Diagnostic Trouble Code (DTC) will be stored in ECM. See TESTING PROCEDURE under SELF-DIAGNOSTIC SYSTEM in appropriate SELF-DIAGNOSTICS article for retrieval of DTCs. EVAP Vacuum Switching Valve (VSV) is used to control EVAP system. ECM operates EVAP VSV which controls vacuum flow for EVAP operation. For EVAP system and component testing, see FUEL EVAPORATIVE SYSTEM under EMISSION SYSTEMS & SUB-SYSTEMS in appropriate SYSTEM & COMPONENT TESTING article. ON-BOARD REFILLING VAPOR RECOVERY SYSTEM
Avalon, Camry, Camry Solara, Celica, Corolla, ECHO, Highlander, MR2, Prius, RAV4, Sequoia, Sienna, Tacoma & 4Runner

On-board Refilling Vapor Recovery (ORVR) system is used to recover fuel vapors into EVAP canister that are generated during refueling. ORVR system consists of fuel inlet pipe, overfill check valve and EVAP canister. See Fig. 68 . When fuel tank cap is removed, atmospheric pressure is applied to port "A" on overfill check valve. See Fig. 69 . Overfill check valve may also be referred to as ORVR-OCKV, fuel tank overfill check valve or fill check valve. When fuel flows into fuel inlet pipe and fuel tank, the pressure in fuel tank increases. Increased pressure in fuel tank causes valve "B" on overfill valve to open, allowing fuel vapors to flow into EVAP canister. When fuel tank is full, valve "C" closes, shutting off vapor flow to EVAP canister.

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Fig. 68: Identifying Typical On-board Refilling Vapor Recovery System Components (Avalon, Camry, Camry Solara, Celica, Corolla, ECHO, Highlander, MR2, Prius, RAV4, Sequoia, Sienna, Tacoma & 4Runner) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 69: Locating Port & Valves On Overfill Valve, & Identifying Vapor Flow (Avalon, Camry, Camry Solara, Celica, Corolla, ECHO, Highlander, MR2, Prius, RAV4, Sequoia, Sienna, Tacoma & 4Runner) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. POSITIVE CRANKCASE VENTILATION

2002 ENGINE PERFORMANCE Theory & Operation

Positive Crankcase Ventilation (PCV) system prevents crankcase vapors from escaping into the atmosphere. Crankcase vapors are routed from crankcase through a vacuum-controlled PCV valve, then delivered back into the cylinders. PCV system provides primary control of crankcase blow-by vapors, according to manifold vacuum. When manifold vacuum is high (at idle), PCV restricts vapor flow to maintain a smooth idle condition.

SELF-DIAGNOSTIC SYSTEMS
Engine Control Module (ECM) is equipped with a self-diagnostic system. By analyzing various input signals, ECM detects system malfunctions related to various operating parameters. When malfunction of various engine sensors, switches or circuits occurs, a Diagnostic Trouble Code (DTC) may be stored in the ECM memory. DTC may be retrieved for system diagnosis. For additional information on self-diagnostic system, see SELF-DIAGNOSTIC SYSTEM in appropriate SELF-DIAGNOSTICS article for retrieving of DTCs. MALFUNCTION INDICATOR LIGHT All vehicles are equipped with a Malfunction Indicator Light (MIL). MIL may also be referred to as CHECK ENGINE light and is displayed as an engine icon on instrument cluster. MIL will momentarily illuminate when ignition is first turned on to do a bulb check. MIL may illuminate when systems related to emission controls are malfunctioning during normal vehicle operation. For additional information on MIL operation, see SELF-DIAGNOSTIC SYSTEM in appropriate SELF-DIAGNOSTICS article.

VARIABLE VALVE LIFT SYSTEM

NOTE: Variable Valve Lift (VVL) system may also be referred to as Variable Valve Timing Lift Intelligent (VVTL-I or VVTL-i) system.

CELICA (1.8L 2ZZ-GE) Variable Valve Lift (VVL) system controls amount of intake and exhaust valve lift while engine is operating at high speeds to provide improved engine performance and fuel economy. VVL system consists of camshaft timing Oil Control Valve (OCV), camshaft changeover mechanism, camshaft position sensor, crankshaft position sensor, engine coolant temperature sensor, camshafts with low-and-medium-speed camshaft lobes and high-speed camshaft lobes, Engine Control Module (ECM) and associated wiring. See Fig. 70 . NOTE: OCV for VVL system may also be referred to as camshaft timing oil control valve (VVL) or Variable Valve Lift (VVL) oil control valve.

When engine is operating in low-to-medium-speed range, low-and-medium-speed camshaft lobes operate to move the valves by using needle roller and rocker arm on camshaft changeover mechanism. See Fig. 70 . The high-speed camshaft lobes also push downward on the rocker arm pad, but because rocker arm pad moves freely, this movement of high-speed camshaft lobes does not cause the rocker arm to move the valves. When engine coolant temperature is greater than 140F (60C) with engine speed greater than 6000 RPM, the ECM operates oil control valve for VVL system to allow oil pressure to be applied to the rocker arm pin. See Fig. 70 . When oil pressure is applied to rocker arm pin, rocker arm pin is pushed to the locked position. This prevents rocker arm pad from moving freely, this changes operation from low-and-mediumspeed camshaft lobes to the high-speed camshaft lobes. This provides more valve lift for improved engine performance and fuel economy.

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Oil control valve for VVT is an electrically controlled valve that receives oil pressure from the oil pump. See Fig. 71 . When engine is operating in low-to-medium-speed range, ECM operates oil control valve to move spool valve to open position. This allows oil pressure to drain instead of being applied to rocker arm pin for use of high-speed camshaft lobes. When engine coolant temperature is greater than 140F (60C) with engine speed greater than 6000 RPM, ECM operates oil control valve to move spool valve to the closed position. This allows oil pressure to be applied to rocker arm pin for use of the high-speed camshaft lobes. The ECM uses input signals for engine speed, intake air volume, throttle position and engine coolant temperature to determine operation of oil control valve for VVT. If a problem exists in the VVL system, a Diagnostic Trouble Code (DTC) may be stored in ECM. See TESTING PROCEDURE under SELFDIAGNOSTIC SYSTEM in appropriate SELF-DIAGNOSTICS article for retrieving of DTCs.

2002 ENGINE PERFORMANCE Theory & Operation

Fig. 71: Cross-Sectional View Of Oil Control Valve For Variable Valve Lift System (Celica 1.8L 2ZZGE) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

VARIABLE VALVE TIMING SYSTEM

NOTE: Variable Valve Timing (VVT) system may also be referred to as Variable Valve Timing Intelligent (VVT-I or VVT-i) system.

AVALON, HIGHLANDER 3.0L V6 & SIENNA Variable Valve Timing (VVT) system controls intake camshaft valve timing to provide improved engine performance and fuel economy, and reduce exhaust emissions. VVT system consists of 2 camshaft timing oil control valves, variable valve timing controller on each intake camshaft, crankshaft position sensor, engine coolant temperature sensor, Engine Control Module (ECM), variable valve timing sensors and associated wiring. See Fig. 72 . NOTE: Camshaft timing oil control valve may also be referred to as VVT camshaft timing oil control valve, camshaft timing oil control valve VVT, oil control valve for VVT or VVT Oil Control Valve (OCV). Variable valve timing controller may also be referred to as variable valve timing actuator or VVT controller.

Exhaust camshaft is driven by the timing belt and intake camshaft is driven by gear on the end of exhaust

2002 ENGINE PERFORMANCE Theory & Operation

camshaft. Intake camshaft drive gear is integrated with the variable valve timing controller to vary intake camshaft valve timing. Variable valve timing controller consists of a housing driven from the exhaust camshaft and a vane that is fixed on the intake camshaft. See Fig. 73 . Oil pressure may be delivered from the advance or retard side of intake camshaft to the variable valve timing controller. This oil pressure causes variable valve timing controller to rotate intake camshaft and change the valve timing. When engine is stopped, intake camshaft will be placed in the most retarded state, to improve low speed stability. At this time, a lock pin secures the housing and the vane inside variable valve timing controller. After the engine starts, lock pin is released by oil pressure. Camshaft timing oil control valve is an electrically controlled valve that receives oil pressure from the oil pump. See Fig. 74 . The ECM uses input signals for engine speed, intake air volume, throttle position and engine coolant temperature to determine operation of camshaft timing oil control valve. The ECM also uses input signals from variable valve timing sensors and crankshaft position sensor for determining the actual intake camshaft valve timing. Variable valve timing sensors may also be referred to as camshaft position sensors. The ECM operates camshaft timing oil control valve by controlling position of spool valve. This determines which side of variable valve timing controller the oil pressure will be applied on for advancing or retarding the valve timing by rotating the intake camshaft. See Fig. 74 . When engine is stopped, camshaft timing oil control valve is in the retarded state. When engine is idling, intake camshaft valve timing is set at the standard or hold position to stabilize the idle and obtain better fuel economy. During light engine load, intake camshaft valve timing remains retarded to provide stable engine operation. During medium engine load, intake camshaft valve timing is advanced to provide increased performance, fuel economy and improved emission control. During heavy engine load in low-to-medium-speed range, intake camshaft valve timing is advanced to provide increased torque. During heavy engine load in high-speed range, intake camshaft valve timing is retarded to provide improved highspeed range operation and better fuel economy. During cold temperatures, intake camshaft valve timing remains at the standard or hold position to stabilize fast idle speed and obtain better fuel economy. When engine is started or stopped, intake camshaft valve timing is set at retarded position to improve engine starting. If a problem exists in the VVT system, a Diagnostic Trouble Code (DTC) may be stored in ECM. See TESTING PROCEDURE under SELF-DIAGNOSTIC SYSTEM in appropriate SELF-DIAGNOSTICS article for retrieving of DTCs.

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Fig. 74: Cross-Sectional View Of Typical Camshaft Timing Oil Control Valve (Avalon, Camry 2.4L 4Cyl., Camry Solara 2.4L 4-Cyl., Celica, Corolla, ECHO, Highlander, MR2, Prius, RAV4 & Sienna) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. CAMRY 2.4L 4-CYL., CAMRY SOLARA 2.4L 4-CYL., CELICA, COROLLA, ECHO, HIGHLANDER 2.4L 4-CYL., MR2, PRIUS & RAV4 Variable Valve Timing (VVT) system controls intake camshaft valve timing to provide improved engine performance, fuel economy, and reduced exhaust emissions. VVT system consists of camshaft timing oil control valve, variable valve timing controller on intake camshaft, crankshaft position sensor, Engine Control Module (ECM), camshaft position sensor and associated wiring. See Fig. 75 -Fig. 77 . NOTE: Camshaft timing oil control valve may also be referred to as oil control valve for VVT, VVT Oil Control Valve (OCV) or camshaft timing oil control valve VVT. Variable valve timing controller may also be referred to as variable valve timing actuator or VVT controller.

Intake and exhaust camshaft are driven by a timing chain and drive gear on each camshaft. Intake camshaft drive gear is integrated with the variable valve timing controller to vary intake camshaft valve timing. Variable valve timing controller consists of a housing which is driven from the timing chain and a vane that is fixed on the intake camshaft. See Fig. 78 . Oil pressure may be delivered from advance or retard side of intake camshaft to the variable valve timing controller. This oil pressure causes variable valve timing controller to rotate, causing intake camshaft to rotate and change the valve timing. When engine is stopped, to improve stability, intake camshaft remains in the most retarded state. When no oil pressure is applied to variable valve timing controller immediately after engine is started, lock pin prevents movement of variable valve timing controller to prevent a knocking noise. Once engine is started and oil pressure exists at variable

2002 ENGINE PERFORMANCE Theory & Operation

valve timing controller, lock pin is released by the oil pressure. Camshaft timing oil control valve is an electrically controlled valve that receives oil pressure from the oil pump. See Fig. 74 . The ECM uses input signals for engine speed, intake air volume, throttle position and engine coolant temperature to determine operation of camshaft timing oil control valve. The ECM also uses input signals from camshaft position sensor and crankshaft position sensor for determining the actual intake camshaft valve timing. Camshaft position sensor may also be referred to as variable valve timing sensor. The ECM operates camshaft timing oil control valve by controlling position of spool valve. This determines which side of variable valve timing controller the oil pressure will be applied to for advancing or retarding the valve timing by rotating the intake camshaft. See Fig. 74 . When engine is stopped, camshaft timing oil control valve is in the retarded state. When engine is idling, intake camshaft valve timing remains at the standard or hold position to stabilize the idle and obtain better fuel economy. During light engine load, intake camshaft valve timing remains retarded to provide stable engine operation. During medium engine load, intake camshaft valve timing is advanced to provide increased performance, fuel economy and improved emission control. During heavy engine load in low-to-medium-speed range, intake camshaft valve timing is advanced to provide increased torque. During heavy engine load in high-speed range, intake camshaft valve timing is retarded to provide improved highspeed range operation and better fuel economy. During cold temperatures, intake camshaft valve timing is set at the standard or hold position to stabilize fast idle speed and obtain better fuel economy. When engine is started or stopped, intake camshaft valve timing is remains at retarded position to improve engine starting. If a problem exists in the VVT system, a Diagnostic Trouble Code (DTC) may be stored in ECM. See TESTING PROCEDURE under SELF-DIAGNOSTIC SYSTEM in appropriate SELF-DIAGNOSTICS article for retrieving of DTCs.

2002 ENGINE PERFORMANCE Theory & Operation

Fig. 76: Locating Variable Valve Timing System Components (Celica, Corolla & MR2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 ENGINE PERFORMANCE Theory & Operation

Fig. 78: Identifying Variable Valve Timing Controller Components (Camry 2.4L 4-Cyl., Camry Solara 2.4L 4-Cyl., Celica, Corolla, ECHO, Highlander 2.4L 4-Cyl., MR2, Prius & RAV4) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

MISCELLANEOUS CONTROLS
NOTE: Although not considered true engine performance-related systems, some controlled devices may affect driveability if they malfunction.

ACTIVE CONTROL ENGINE MOUNT

Avalon & Highlander 3.0L V6

Active control engine mount is used to reduce engine vibration and noise when engine is idling. Active control engine mount consists of vacuum tank, active control engine mount, Engine Control Module (ECM) and Active Control Mount (ACM) Vacuum Switching Valve (VSV). See Fig. 79 . Operating range of active control engine mount is during idling when engine speed is less than 900 RPM. ACM VSV receives vacuum supply from the vacuum tank. Signals that are synchronized to engine speed are delivered from the ECM to the ACM VSV. Engine vacuum is used to vary the pressure in active control engine mount. As a result, the diaphragm in active control engine mount vibrates and uses the liquid in the main liquid chamber to control engine mount vibration. The force of the vibration in the active control engine mount is regulated by the orifice and the side branch which vents out to the atmosphere. Vibration of

2002 ENGINE PERFORMANCE Theory & Operation

NOTE:
Avalon

IG2 relay may also be referred to as ignition relay.

IG2 fuse supplies constant battery voltage to one side of IG2 relay. When ignition is turned on, voltage is supplied from ignition switch to other side of IG2 relay to energize the IG2 relay. When IG2 relay is energized, it provides battery voltage to fuel injectors and ignition coils. IG2 relay is located in fuse/relay box at driver's side front corner of engine compartment.
Celica

IG2 fuse supplies constant battery voltage to one side of IG2 relay. When ignition is turned on, voltage is supplied from ignition switch to other side of IG2 relay to energize the IG2 relay. When IG2 relay is energized, it provides battery voltage to fuel injectors and ignition coils. IG2 relay is located in fuse/relay box at driver's side front corner of engine compartment, just in front of strut tower.
MR2

IG2 fuse supplies constant battery voltage to one side of IG2 relay. When ignition is turned on, voltage is supplied from ignition switch to other side of IG2 relay to energize the IG2 relay. When IG2 relay is energized, it provides battery voltage to fuel injectors, ignition coils and IGSW terminal of Engine Control Module (ECM). IG2 relay is located in relay box on firewall at driver's side front corner of engine compartment.
Prius

AM2 fuse supplies constant battery voltage to one side of IG2 relay. When ignition is turned on, voltage is supplied from ignition switch to other side of IG2 relay to energize the IG2 relay. When IG2 relay is energized, it provides battery voltage to fuel injectors and ignition coils. IG2 relay is located in fuse/relay box at driver's side front corner of engine compartment.
RAV4

IGN fuse supplies constant battery voltage to one side of IG2 relay. When ignition is turned on, voltage is supplied from ignition switch, through IG2 fuse and to other side of IG2 relay to energize the IG2 relay. When IG2 relay is energized, it provides battery voltage to fuel injectors and ignition coils. IG2 relay is located in relay box at driver's side front corner of engine compartment, just in front of strut tower. POSITIVE TEMPERATURE COEFFICIENT HEATER
ECHO

Positive Temperature Coefficient (PTC) heater is a small electrical heater located in the heater core and is used on vehicles equipped for cold areas. See Fig. 80 . PTC heater may be turned on if all of the following conditions exist: temperature control switch is at MAX HOT position, engine speed is more than 1050 RPM, engine coolant temperature is less than 176F (80C) and generator power ratio is less than 95 percent. PTC heater may also be turned on and off depending on generator power ratio. Temperature control switch operates a maximum hot switch, which provides an input signal to Engine Control Module (ECM) for controlling PTC heater operation. Maximum hot switch may also be referred to as MAX HOT switch.

2002 ENGINE PERFORMANCE Theory & Operation

HTR SUB1 relay is used for supplying battery voltage to PTC heater. HTR SUB1 relay may also be referred to as heater sub relay. HTR SUB1 fuse supplies battery voltage to one side of HTR SUB1 relay. When ignition is turned on, voltage is supplied from ignition switch, through ECU-IG fuse and to other side of HTR SUB1 relay. When PTC amplifier completes ground circuit for HTR SUB1 relay, HTR SUB1 relay then provides battery voltage to PTC heater for PTC heater operation. HTR SUB1 relay is located in fuse/relay box at driver's side front corner of engine compartment, just in front of strut tower.

Fig. 80: Locating Positive Temperature Coefficient Heater (ECHO) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. TRANSMISSION/TRANSAXLE CONTROLS NOTE: Only electronically controlled automatic transmissions or transaxles are covered. Some models have automatic transmissions or transaxles which are not electronically controlled.

Electronically Controlled Transmission/Transaxle

2002 ENGINE PERFORMANCE Theory & Operation

Engine Control Module (ECM) uses input signals for controlling automatic transmission or transaxle operation.

2002 ENGINE PERFORMANCE Vacuum Diagrams

2002 ENGINE PERFORMANCE Vacuum Diagrams

INTRODUCTION
This article contains underhood views or schematics of vacuum hose routing. Use these vacuum diagrams during the visual inspection in appropriate BASIC DIAGNOSTIC PROCEDURES article. This will assist in identifying improperly routed vacuum hoses, which may cause driveability and/or computer-indicated malfunctions. NOTE: When using vacuum diagrams, the charcoal canister may also be referred to as canister or EVAP canister.

Fig. 1: Vacuum Diagram (Avalon 3.0L V6 - 1 Of 3) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 ENGINE PERFORMANCE Vacuum Diagrams

Fig. 15: Vacuum Diagram (Corolla 1.8L 4-Cyl. - 1 Of 3) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 16: Vacuum Diagram (Corolla 1.8L 4-Cyl. - 2 Of 3) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 ENGINE PERFORMANCE Vacuum Diagrams

Fig. 17: Vacuum Diagram (Corolla 1.8L 4-Cyl. - 3 Of 3) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 ENGINE PERFORMANCE Wiring Diagrams

COROLLA

Fig. 34: Wiring Diagram (Corolla 1.8L 3-Speed A/T & M/T - 1 Of 3)

2002 ENGINE PERFORMANCE Wiring Diagrams

Fig. 35: Wiring Diagram (Corolla 1.8L 3-Speed A/T & M/T - 2 Of 3)

2002 ENGINE PERFORMANCE Wiring Diagrams

Fig. 36: Wiring Diagram (Corolla 1.8L 3-Speed A/T & M/T - 3 Of 3)

2002 ENGINE PERFORMANCE Wiring Diagrams

Fig. 37: Wiring Diagram (Corolla 1.8L 4-Speed A/T - 1 Of 3)

2002 ENGINE PERFORMANCE Wiring Diagrams

Fig. 38: Wiring Diagram (Corolla 1.8L 4-Speed A/T - 2 Of 3)

2002 ENGINE PERFORMANCE Wiring Diagrams

Fig. 39: Wiring Diagram (Corolla 1.8L 4-Speed A/T - 3 Of 3)

2002 ENGINE COOLING Specifications & Drive Belt Routing

2002 ENGINE COOLING Specifications & Drive Belt Routing

COOLING SYSTEM BLEEDING

NOTE: Whenever cooling system is drained on Celica, special cooling system bleeding procedure needs to be followed. No special procedure is required for any other models.

CELICA NOTE: The following procedure assumes that cooling system has been completely drained by loosening radiator drain plug on bottom of radiator, and engine drain plug on the coolant drain union located on left rear of cylinder block.

1. Remove upper front fender apron cover and upper radiator support cover to access radiator coolant reservoir tank and hoses. Loosen 2 coolant reservoir bolts and 3 reservoir hose retaining clamps. Raise coolant reservoir and place on top of air cleaner cover. Support reservoir from above with wire to prevent reservoir from falling. 2. Remove cooling system bleed plug. Ensure radiator drain plug and engine drain plug on coolant drain union are closed. Add approximately 4 qts. (3.7L) of 50/50 mix of water (preferably distilled water) and coolant to reservoir tank. DO NOT use plain water or alcohol base coolant. Continue to add water/coolant mixture as necessary. If cooling system does not require approximate refill capacity to maintain coolant in reservoir at the FULL mark, air exists in system or system was not properly drained. See 4-CYLINDER COOLING SYSTEM SPECIFICATIONS table. 3. If cooling system will not take additional coolant, squeeze lower radiator hose while blocking off bleed plug opening with finger. Continue to do this while slowly adding coolant. Start engine with reservoir cap and bleed plug removed. Ensure A/C switch is in OFF position, if equipped. Run engine until cooling fan comes on and goes off one time. Add additional coolant to reservoir as necessary. 4. Install bleed plug and reservoir cap. Rotate reservoir cap 2 1/2 turns until click is heard. Increase engine speed to 3000 RPM for 5 seconds, and then allow to idle for 5 seconds. Repeat this procedure for at least 15 minutes. Turn off engine and allow engine to cool completely. With engine completely cooled, coolant level in reservoir should be between LOW and FULL marks. Next time engine warms to normal operating temperature, coolant reservoir level should be above the FULL mark. 5. Reinstall engine coolant reservoir. Reinstall covers. Check for coolant leaks.

DRIVE BELT ROUTING

Automatic belt tension is used to provide proper tension on serpentine drive belt. For serpentine drive belt routing, see Fig. 1 -Fig. 3 .

2002 ENGINE COOLING Specifications & Drive Belt Routing

Fig. 2: Drive Belt Routing (Celica, Corolla, MR2 & RAV4) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 ENGINE COOLING Specifications & Drive Belt Routing

Fig. 3: Drive Belt Routing (Land Cruiser, Sequoia & Tundra 4.7L V8) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

SPECIFICATIONS
BELT ADJUSTMENT Ensure all drive belts are adjusted to proper tension. See appropriate BELT ADJUSTMENT table. On models with an automatic belt tensioner, no adjustment is necessary, but serpentine drive belt must be properly installed. 4-CYLINDER BELT ADJUSTMENT - Tension In Lbs. (kg) Using Belt Tension Gauge Application Camry & Camry Solara Drive Belt Celica & Corolla Drive Belt ECHO A/C Generator Power Steering Highlander & MR2 Drive Belt Prius A/C Water Pump RAV4 Drive Belt Tacoma A/C Generator Power Steering (1) Used belt is a belt in operation at least 5 minutes. New Belt
(2) (2) (1) Used Belt (2) (2)

110-154 (50-70) 121-143 (55-65) 100-121 (45-55)

(2)

77-100 (35-45) 55-88 (25-40) 55-77 (25-35)

(2)

99-121 (44-55) 99-121 (44-55)

(2)

57-77 (26-35) 57-77 (26-35)

(2)

135-185 (61-84) 116-169 (53-76) 135-180 (61-82)

80-120 (36-54) 66-88 (30-40) 85-120 (39-54)

(2) Automatic belt tensioner is used. Adjustment is not required.

V6 BELT ADJUSTMENT - Tension In Lbs. (kg) Using Belt Tension Gauge Application Avalon A/C Generator Power Steering Camry A/C New Belt 143-187 (65-85) 170-180 (77-82) 120-185 (54-84) 138-192 (63-87)
(1) Used Belt

66-110 (30-50) 95-135 (43-61) 95-135 (43-61) 66-110 (30-50)

2002 ENGINE COOLING Specifications & Drive Belt Routing

Generator Power Steering Camry Solara A/C Generator Power Steering Highlander A/C Generator Power Steering Sienna A/C Generator Power Steering Tacoma & 4Runner A/C Generator Power Steering Tundra A/C Generator Power Steering (1) Used belt is a belt in operation at least 5 minutes.

138-192 (63-87) 146-190 (66-86) 138-192 (63-87) 170-180 (77-82) 150-185 (68-84) 138-192 (63-87) 138-192 (63-87) 146-190 (66-86) 138-192 (63-87) 170-180 (77-82) 150-185 (68-84) 135-185 (61-84) 140-180 (64-82) 135-180 (61-82) 135-185 (61-84) 135-185 (61-84) 135-180 (61-82)

66-110 (30-50) 73-117 (33-53) 99-121 (44-55) 95-135 (43-61) 95-135 (43-61) 66-110 (30-50) 66-110 (30-50) 73-117 (33-53) 66-110 (30-50) 95-135 (43-61) 95-135 (43-61) 80-120 (36-54) 80-120 (36-54) 85-120 (39-54) 80-120 (36-54) 80-120 (36-54) 85-120 (39-54)

V8 BELT ADJUSTMENT - Tension In Lbs. (kg) Using Belt Tension Gauge Application Land Cruiser, Sequoia & Tundra Drive Belt
(1) Used belt is a belt in operation at least 5 minutes. (2) Automatic belt tensioner is used. Adjustment is not required. Belt must be replaced if arrow mark

New Belt
(2)

(1) Used Belt (2)

on automatic belt tensioner is not within area "A". See Fig. 4 .

2002 ENGINE COOLING Specifications & Drive Belt Routing

Fig. 4: Locating Arrow Mark On Automatic Belt Tensioner (Land Cruiser, Sequoia & Tundra 4.7L) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. COOLING SYSTEM SPECIFICATIONS 4-CYLINDER COOLING SYSTEM SPECIFICATIONS Application Coolant Replacement Interval Coolant Capacity Camry & Camry Solara Celica 1ZZ-FE A/T M/T 2ZZ-GE A/T M/T

Specification 30,000 Miles Or 24 Months 6.6 Qts. (6.2L)

5.9 Qts. (5.6L) 6.0 Qts. (5.7L) 6.1 Qts. (5.8L) 6.2 Qts. (5.9L)

2002 ENGINE COOLING Specifications & Drive Belt Routing

Corolla A/T M/T ECHO A/T M/T Highlander MR2 Prius RAV4 A/T M/T Tacoma 2WD PreRunner A/T M/T Except PreRunner A/T M/T 4WD A/T M/T 4Runner With Rear Heater Without Rear Heater Pressure Cap Standard Opening Pressure Camry & Highlander Camry Solara, Corolla, Prius & Tacoma Celica, ECHO, MR2 & RAV4 Thermostat Opening Temperature Camry, Camry Solara, Celica, ECHO, Highlander, MR2, Prius, RAV4 & Tacoma Corolla
(1) Minimum opening pressure is 11.2 psi (.78 kg/cm2 ). (2) Minimum opening pressure is 8.5 psi (.59 kg/cm2 ). (3) Minimum opening pressure is 11.5 psi (.80 kg/cm2 ).

6.0 Qts. (5.7L) 6.1 Qts. (5.8L) 4.5 Qts. (4.3L) 4.7 Qts. (4.4L) 6.8 Qts. (6.4L) 11.0 Qts. (10.4L) 5.2 Qts. (4.9L) 6.6 Qts. (6.2L) 6.7 Qts. (6.3L)

8.7 Qts. (8.2L) 8.8 Qts. (8.3L) 8.2 Qts. (7.8L) 8.5 Qts. (8.0L) 8.7 Qts. (8.2L) 8.8 Qts. (8.3L) 9.5 Qts. (9.0L) 8.5 Qts. (8.0L)
(1) 13.4-17.6 psi (.95-1.25 kg/cm2 ) (2) 10.7-14.9 psi (.75-1.05 kg/cm2 ) (3) 13.5-17.8 psi (.96-1.25 kg/cm2 )

176-183F (80-84C) 165-173F (74-78C)

V6 COOLING SYSTEM SPECIFICATIONS Application Coolant Replacement Interval Coolant Capacity

Specification 30,000 Miles Or 24 Months

2002 ENGINE COOLING Specifications & Drive Belt Routing

Avalon Camry & Camry Solara Highlander Sienna Tacoma 2WD PreRunner A/T M/T Except PreRunner 4WD A/T M/T Tundra 4Runner With Rear Heater Without Rear Heater Pressure Cap Standard Opening Pressure Avalon, Camry, Camry Solara & Sienna Highlander Tacoma & 4Runner Thermostat Opening Temperature
(1) Minimum opening pressure is 10.0 psi (.70 kg/cm2 ). (2) Minimum opening pressure is 11.2 psi (.78 kg/cm2 ). (3) Minimum opening pressure is 8.8 psi (.62 kg/cm2 ).

9.5 Qts. (9.0L) 9.7 Qts. (9.2L) 9.9 Qts. (9.4L) 11.0 Qts. (10.4L)

10.5 Qts. (10.0L) 10.7 Qts. (10.1L) 10.3 Qts. (9.7 L) 10.5 Qts. (9.9L) 10.7 Qts. (10.1L) 10.5 Qts. (9.9L) 9.5 Qts. (9.0L) 8.5 Qts. (8.0L)
(1) 12.1-16.4 psi (.85-1.15 kg/cm2 ) (2) 13.4-17.8 psi (.95-1.25 kg/cm2 ) (3) 10.7-14.9 psi (.75-1.05 kg/cm2 )

176-183F (80-84C)

V8 COOLING SYSTEM SPECIFICATIONS Application Coolant Replacement Interval Coolant Capacity Land Cruiser With Front Heater Only With Front & Rear Heater Sequoia With Front Heater Only With Front & Rear Heater Tundra Pressure Cap Standard Opening Pressure Land Cruiser Sequoia & Tundra

Specification 30,000 Miles Or 24 Months

15.5 Qts. (14.7L) 16.3 Qts. (15.4L) 12.4 Qts. (11.7L) 14.1 Qts. (13.4L) 12.3 Qts. (11.6L)
(1) 13.4-17.8 psi (.95-1.25

kg/cm2 )
(2) 10.7-14.9 psi (.75-1.05

kg/cm2 )

2002 ENGINE COOLING Specifications & Drive Belt Routing

Thermostat Opening Temperature

(1) Minimum opening pressure is 11.4 psi (.80 kg/cm2 ). (2) Minimum opening pressure is 8.6 psi (.60 kg/cm2 ).

176-183F (80-84C)

2002 ENGINE COOLING Electric Cooling Fans - Corolla

2002 ENGINE COOLING Electric Cooling Fans - Corolla

DESCRIPTION & OPERATION

Fans are controlled via Engine Coolant Temperature (ECT) switches/sensors. For cooling fan operating conditions, see COOLING FAN OPERATING CONDITIONS table. COOLING FAN OPERATING CONDITIONS Application & Temperature - F (C) More Than 199 (93) Less Than 181 (83) FAN MOTOR OPERATION When the ignition switch is turned on, the current from the ECU-IG fuse flows to the FAN No. 1 relay (coil side) and the A/C FAN No. 2 relay (coil side) to terminal No. 3 of the A/C single pressure switch to terminal No. 2 to engine control module. Electric current passed to engine control module receives the signal from engine coolant temperature (ECT) sensor and is sent from engine control module to ground, and the FAN No. 1 relay is turned off and the A/C FAN No. 2 relay is turned on. At the same time as this current flow, the current from the ECU-IG fuse flows to the ENGINE MAIN relay (coil side) to ground, turning the ENGINE MAIN relay on. As a result, current from the FL ALT fuse flows to the CDS fuse and RDI fuse. LOW/HIGH SPEED OPERATION 1. Low Speed Operation - When the ignition switch is turned on and the A/C is activated, the current flows from the FL ALT fuse to the HTR fuse to the HTR relay (point side) to the A/C fuse to the A/C MG relay (point side) to the A/C FAN No. 3 relay (coil side) to ground, turning the A/C FAN No. 3 relay on. As a result, the current from the CDS fuse flows to terminal No. 2 of the A/C condenser fan motor to terminal No. 1 to the A/C FAN No. 2 relay (point side) to the A/C FAN No. 3 relay (point side) to terminal No. 2 of the radiator fan motor to terminal No. 1 to ground. As a result, the fans are activated at low speed. If the engine coolant temperature is approximately 194F (90C) or less, and the refrigerant pressure is approximately 220 psi (15.5 kgf/cm2) or less, both the water temperature switch (Radiator fan) and the A/C single pressure switch are closed, so the FAN No. 1 relay is turned off and the A/C FAN No. 2 relay is turned on. As a result, each fan motor operates at low speed. 2. High Speed Operation - During A/C operation, if the refrigerant pressure becomes higher than ordinary level (approximately 220 psi (15.5 kgf/cm2)), the A/C single pressure switch is turned off. As a result, the FAN No. 1 relay is turned on and the A/C FAN No. 2 relay is turned off, and the current flows from the RDI fuse to FAN No. 1 relay (point side) to terminal No. 2 of the radiator fan motor to terminal No. 1 to ground, and the current from the CDS fuse flows to terminal No. 2 of the A/C condenser fan motor to terminal No. 1 to A/C FAN No. 2 relay (point side) to ground, reaching each fan motor in parallel, thus causing the fan motors to operate at high speed. NOTE: Because the current flows in the same manner even if the engine coolant temperature is approximately 194F (90C) or higher, the fan motors still operate at high speed.

Cooling Fan Operation On Off

COMPONENT LOCATIONS

2002 ENGINE COOLING Electric Cooling Fans - Corolla

Corolla uses 2 electric cooling fans located directly behind the radiator. See ELECTRIC COOLING FAN IDENTIFICATION . For electrical component locations, see ELECTRICAL COMPONENT LOCATOR article For relay box, circuit breaker and fuse locations, see FUSES & CIRCUIT BREAKERS - COROLLA . ELECTRIC COOLING FAN IDENTIFICATION Application Condenser Cooling Fan Radiator Cooling Fan

Cooling Fan Location Passenger's Side, Rear Of Radiator Driver's Side, Rear Of Radiator

SYSTEM TESTS
ELECTRIC COOLING FAN
Cooling Fan Operation With Low Temperature (Below 181F (83C))

1. With engine coolant temperature less than 181F (83C), turn ignition switch to ON position (engine off). Ensure fan stops. 2. If fan does not stop, test cooling fan relay and ECT switch. See COOLING FAN RELAYS and ECT SWITCH . Check for loose or broken connector or wiring between relay and ECT switch. Repair as necessary. 3. Disconnect ECT switch connector. See ECT SWITCH LOCATIONS table. With ignition still in ON position, ensure cooling fan turns on. If not, check fuses, engine main relay, cooling fan relay, and cooling fan motor. Check for short between cooling fan relay and ECT switch. ECT SWITCH LOCATIONS Application Corolla

ECT Switch Location Rear Of Engine On Water Outlet

Cooling Fan Operation With High Temperature (Above 199F (93C))

1. Reconnect ECT switch connector. Start engine and increase coolant temperature to more than 199F (93C). Ensure cooling fan turns. If not, replace ECT switch/sensor.
Inspect Cooling Fan

1. Stop engine and disconnect No. 1 cooling fan 2-pin connector. With battery connected to ammeter (positive battery terminal to positive ammeter terminal and negative battery and negative ammeter terminals to each connector pin), test amperage readings. See Fig. 1 . If readings are not as specified, replace cooling fan. See COOLING FAN CURRENT DRAW SPECIFICATIONS table. Reconnect No. 1 fan connector. 2. Disconnect No. 2 cooling fan 2-pin connector. With battery connected to ammeter (positive battery terminal to positive ammeter terminal and negative battery and negative ammeter terminals to each connector pin), test amperage readings. See Fig. 1 . If readings are not as specified, replace cooling fan. See COOLING FAN CURRENT DRAW SPECIFICATIONS table. Reconnect No. 2 fan connector. COOLING FAN CURRENT DRAW SPECIFICATIONS Application

Amps @ 68F (20C)

2002 ENGINE COOLING Electric Cooling Fans - Corolla

Corolla

5.2-8.2

2002 ENGINE COOLING Electric Cooling Fans - Corolla

2002 ENGINE COOLING Electric Cooling Fans - Corolla

Fig. 1: Testing Amperage At Fan Connectors Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

COMPONENT TESTS
CAUTION: When battery is disconnected, vehicle computer and memory systems may lose memory data. Driveability problems may exist until computer systems have completed a relearn cycle. See COMPUTER RELEARN PROCEDURES article in GENERAL INFORMATION before disconnecting battery. COOLING FAN RELAYS NOTE: Place match marks on all relays for proper reinstallation.

Cooling Fan Relay No. 1

1. Disconnect negative battery cable. Remove cooling fan relay No. 1 from fuse/relay box. See Fig. 2 . Using an ohmmeter, check for continuity between relay terminals No. 1 and 2, and No. 3 and 4. See Fig. 3 . If no continuity exists, replace relay. 2. To check relay operation, connect positive battery voltage to terminal No. 1 and ground to terminal No. 2. Check that no continuity exists between relay terminals No. 3 and 4. If continuity exists, replace relay. Reinstall cooling fan relay No. 1.
Cooling Fan Relay No. 2

1. Disconnect negative battery cable. Remove cooling fan relay No. 2 from fuse/relay box. See Fig. 2 . Using an ohmmeter, check for continuity between relay terminals No. 1 and 2, and No. 3 and 4. See Fig. 3 . If no continuity exists, replace relay. Check that no continuity exists between relay terminals No. 3 and 5. If continuity exists, replace relay. 2. To check relay operation, connect positive battery voltage to terminal No. 1 and ground to terminal No. 2. Check that no continuity exists between relay terminals No. 3 and 4. If continuity exists, replace relay. Check for continuity between relay terminals No. 3 and 5. If no continuity exists, replace relay. Reinstall cooling fan relay No. 2.
Cooling Fan Relay No. 3

1. Disconnect negative battery cable. Remove cooling fan relay No. 3 from fuse/relay box. See Fig. 2 . Using an ohmmeter, check for continuity between relay terminals No. 1 and 2. See Fig. 3 . If no continuity exists, replace relay. Check that no continuity exists between relay terminals No. 3 and 5. If continuity exists, replace relay. 2. To check relay operation, connect positive battery voltage to terminal No. 1. Connect ground to terminal No. 2. Check for continuity between relay terminals No. 3 and 5. If no continuity exists, replace relay. Reinstall cooling fan relay No. 3.
Engine Main Relay

1. Disconnect negative battery cable. Remove engine main relay from fuse/relay box. See Fig. 2 . Using an ohmmeter, check for continuity between relay terminals No. 3 and 5, and No. 2 and 4. See Fig. 4 .

2002 ENGINE COOLING Electric Cooling Fans - Corolla

If no continuity exists, replace relay. Check that no continuity exists between relay terminals No. 1 and 2. If continuity exists, replace relay. 2. To check relay operation, connect positive battery voltage to terminal No. 3 and ground to terminal No. 5. Check that no continuity exists between relay terminals No. 2 and 4. If continuity exists, replace relay. Check for continuity between relay terminals No. 1 and 2. If no continuity exists, replace relay. Reinstall engine main relay.

Fig. 2: Identifying Relay Locations Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 ENGINE COOLING Electric Cooling Fans - Corolla

Fig. 3: Identifying Terminals Of Cooling Fan Relays Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 4: Identifying Terminals Of Engine Main Relay Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ENGINE COOLANT TEMPERATURE (ECT) SWITCH

2002 ENGINE COOLING Electric Cooling Fans - Corolla

1. Drain engine coolant. Remove ECT switch. See ECT SWITCH LOCATIONS table. Place ECT switch thermal sensor into a water bath. 2. Using an ohmmeter, check that there is no continuity between ECT switch terminals when coolant temperature is more than 199F (93C). If continuity exists, replace ECT switch. 3. Cool water and check that there is continuity when coolant temperature is less than 181F (83C). If there is no continuity, replace ECT switch. Install switch. Fill with engine coolant. ENGINE COOLANT TEMPERATURE SENSOR 1. Drain engine coolant. Remove ECT sensor. See ECT SENSOR LOCATIONS . Place ECT sensor and thermometer into a water bath. ECT SENSOR LOCATIONS Application Corolla

Sensor Location Rear Of Engine

2. Measure resistance between terminal Nos. 1 and 2. See Fig. 5 . If resistance is not as specified, replace ECT sensor.

2002 ENGINE COOLING Electric Cooling Fans - Corolla

Fig. 5: Measuring ECT Sensor Resistance Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 3. Install NEW gasket on sensor, and install ECT sensor. Fill with engine coolant.

DIAGNOSTIC TESTS
For Diagnostic Trouble Code (DTC) related circuit testing, see DTC P0115: ENGINE COOLANT

2002 ENGINE COOLING Electric Cooling Fans - Corolla

TEMPERATURE SENSOR CIRCUIT under DIAGNOSTIC TESTS under SELF DIAGNOSTICS article in ENGINE PERFORMANCE.

WIRING DIAGRAMS

2002 ENGINE Cooling System (Mechanical) - Corolla

2002 ENGINE Cooling System (Mechanical) - Corolla

COOLANT
INSPECTION NOTE: Check the coolant level when the engine is cold.

1. Check engine coolant level at reservoir. The engine coolant level should be between the "LOW" and "FULL" line. If low, check for leaks and add "Toyota Long Life Coolant" or equivalent up to the "FULL" line. 2. Check engine coolant quality. a. Remove the radiator cap. CAUTION: To avoid the danger of being burned, do not remove the radiator the cap while the engine and radiator are still hot, as fluid and steam can be blown out under pressure. b. There should not be any excessive deposits of rust or scale around the radiator cap or radiator filler hole, and the coolant should be free from oil. If excessively dirty, replace the coolant. c. Reinstall the radiator cap. REPLACEMENT 1. Drain engine coolant. a. Remove the radiator cap. CAUTION: To avoid the danger of being burned, do not remove the radiator cap while the engine and radiator are still hot, as fluid and steam can be blown out under pressure. b. Loosen the radiator drain plug (on the right side of the radiator lower tank) and engine drain plug on the engine coolant drain union (on the left rear of the cylinder block), and drain the coolant.

2002 ENGINE Cooling System (Mechanical) - Corolla

Fig. 1: Locating Radiator & Engine Drain Plugs for Loosening Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Close the drain plugs. Torque: 12.7 N.m (130 kgf.cm, 9 ft.lbf) for engine 2. Fill engine coolant. a. Slowly fill the system with coolant. Use of improper coolants may damage engine cooling system. Use "Toyota Long Life Coolant" or equivalent and mix it with plain water according to the manufactures directions. Use of the coolant which includes more than 50% [freezing protection down to -35 C (31 F)] or 60% [freezing protection down to -50 C (-58 F)] of ethylene-glycol is recommended, but not more than 70%. NOTE:

Do not use an alcohol type coolant or plain water alone. The coolant should be mixed with plain water (preferably deminerali water or distilled water). Capacity:

2002 ENGINE Cooling System (Mechanical) - Corolla

Fig. 2: Displaying Coolant Capacity For M/T & A/T Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Install the radiator cap. c. Start the engine, and bleed the cooling system. d. Refill the engine coolant reservoir with coolant until it reaches "FULL" line. 3. Check for coolant leaks. 4. Check engine coolant specific gravity correctly.

WATER PUMP
COMPONENTS

2002 ENGINE Cooling System (Mechanical) - Corolla

Fig. 3: Identifying Water Pump Components Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL 1. 2. 3. 4. Remove RH engine under cover. Drain engine coolant. Remove drive belt. See step 1) under REMOVAL under GENERATOR. Remove water pump. a. Remove the 6 bolts, water pump and O-ring.

2002 ENGINE Cooling System (Mechanical) - Corolla

Fig. 4: Locating Bolts For Removal Of Water Pump & O-Ring Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Clean up the engine coolant from the water chamber room. NOTE: Do not remove the RH engine mounting bracket and generator when the water pump alone is replaced.

INSPECTION
Inspect Water Pump

a. Visually check the drain hole for coolant leakage. If leakage is found, replace the water pump. b. Turn the pulley, and check that the water pump bearing moves smoothly and quietly. If necessary, replace the water pump.

2002 ENGINE Cooling System (Mechanical) - Corolla

Fig. 5: Turning Pulley Of Water Pump Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSTALLATION 1. Install water pump. a. Place a new O-ring on the timing chain cover. b. Install the water pump with the 6 bolts.

2002 ENGINE Cooling System (Mechanical) - Corolla

Fig. 6: Locating Screws For Installation Of Water Pump Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Torque: 9 N.m (92 kgf.cm, 80 in..lbf) for bolt A 11 N.m (113 kgf.cm, 8 ft.lbf) for bolt B NOTE: Each bolt length is indicated in Fig. 6 . A: 30 mm (1.18 in.) B: 35 mm (1.38 in.) 2. 3. 4. 5. 6. Install rh engine under cover. Install drive belt. See step 2) under INSTALLATION under GENERATOR. Fill with engine coolant. Start engine and check for leaks. Recheck engine coolant level.

2002 ENGINE Cooling System (Mechanical) - Corolla

THERMOSTAT
COMPONENTS

Fig. 7: Identifying Thermostat Components Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL NOTE: Removal of the thermostat would have an adverse effect, causing a lowering

2002 ENGINE Cooling System (Mechanical) - Corolla

of cooling efficiency. Do not remove the thermostat, even if the engine tends to overheat. 1. Drain engine coolant. 2. Remove drive belt and generator. See REMOVAL under GENERATOR. 3. Remove water inlet and thermostat. a. Disconnect the ECT switch connector. b. Remove the 2 nuts, and disconnect the water inlet from the cylinder block.

Fig. 8: Locating Nuts For Removal Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Remove the thermostat. d. Remove the gasket from the thermostat INSPECTION
Inspect Thermostat

NOTE:

The thermostat is numbered with the valve opening temperature.

2002 ENGINE Cooling System (Mechanical) - Corolla

Fig. 9: Displaying Temperature Number On Valve Opening Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. a. Immerse the thermostat in water and gradually heat the water.

2002 ENGINE Cooling System (Mechanical) - Corolla

Fig. 10: Immersing Thermostat In Water Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 ENGINE Cooling System (Mechanical) - Corolla

b. Check the valve opening temperature. Valve opening temperature: 74.0 - 78.5 C (165 - 173 F) If the valve opening temperature is not as specified, replace the thermostat. c. Check the valve lift. Valve lift: 10 mm (0.39 in.) or more at 90 C (194 F) If the valve lift is not as specified, replace the thermostat. d. Check that the valve is fully closed when the thermostat is at low temperatures (below 40 C (104 F)).

Fig. 11: Checking Valve Lift Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 ENGINE Cooling System (Mechanical) - Corolla

If not closed, replace the thermostat. INSTALLATION 1. Place thermostat in cylinder block. a. Install a new gasket to the thermostat. b. Install the thermostat with the jiggle valve upward.

Fig. 12: Installing Jiggle Valve Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE: The jiggle valve may be set within 10 degrees of either side of the prescribed position.

2. Install water inlet. Install the water inlet with the 2 nuts. Torque: 9 N.m (92 kgf.cm, 80 in..lbf) 3. Install generator and drive belt. See INSTALLATION under GENERATOR. 4. Fill with engine coolant.

2002 ENGINE Cooling System (Mechanical) - Corolla

5. Start engine and check for coolant leaks.

RADIATOR
ON-VEHICLE CLEANING Using water or a steam cleaner, remove any mud or dirt from the radiator core. CAUTION: If using a high pressure type cleaner, be careful not to deform the fins of the radiator core (i.e. Maintain a distance between the cleaner nozzle and radiator core). ON-VEHICLE INSPECTION 1. Remove radiator cap. CAUTION: To avoid the danger of being burned, do not remove the radiator cap while the engine and radiator are still hot, as fluid and steam can be blown out under pressure. 2. Inspect radiator cap. NOTE:

If the radiator cap has contaminates, always rinse it with water.

2002 ENGINE Cooling System (Mechanical) - Corolla

Fig. 13: Using Tester At An Angle Of 30 Degrees Or More Above The Horizontal Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Before using a radiator cap tester, wet the relief valve and pressure valve with engine coolant or water. When performing steps and a , keep the tester at an angle of over 30 degrees above the horizontal.

a. Using a radiator cap tester, slowly pump the tester and check that air is coming from the vacuum valve. Pump speed: 1 push (3 seconds or more) NOTE: Push the pump at a constant speed. If air is not coming from the vacuum valve, replace the radiator cap.

b. Pump the tester and measure the relief valve opening pressure. Pump speed: 1 push within 1 seconds NOTE: This pump speed is for the first pump only (in order to close the vacuum valve). After this, the pump speed can be reduced. Standard opening pressure: 74 - 103 kPa (0.75 - 1.05 kgf/cm2 , 10.7 - 14.9 psi) Minimum opening pressure: 59 kPa (0.6 kgf/cm2 , 8.5 psi) Use the tester's maximum reading as the opening pressure. If the opening pressure is less than minimum, replace the radiator cap. 3. Inspect cooling system for leaks. a. Fill the radiator with coolant and attach a radiator cap tester.

2002 ENGINE Cooling System (Mechanical) - Corolla

Fig. 14: Identifying Radiator Cap Tester Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Warm up the engine. c. Pump it to 118 kPa (1.2 kgf/cm2 , 17.1 psi), and check that the pressure does not drop. If the pressure drops, check the hoses, radiator or water pump for leaks. If no external leaks are found, check the heater core, cylinder block and head. 4. Reinstall radiator cap. COMPONENTS

2002 ENGINE Cooling System (Mechanical) - Corolla

Fig. 15: Identifying Radiator Components (1 Of 3) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 ENGINE Cooling System (Mechanical) - Corolla

Fig. 16: Identifying Radiator Components (2 Of 3) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 ENGINE Cooling System (Mechanical) - Corolla

Fig. 17: Identifying Radiator Components (3 Of 3) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL 1. Drain engine coolant. 2. Remove engine under covers. 3. Remove radiator assembly. a. Disconnect the No. 1 electric cooling fan connector. b. Disconnect the No. 2 electric cooling fan connector. c. Disconnect the upper radiator hose. d. Disconnect the lower radiator hose. e. Disconnect the radiator reservoir hose. f. A/T: Disconnect the 2 oil cooler hoses. g. Remove the 2 bolts and upper radiator supports.

2002 ENGINE Cooling System (Mechanical) - Corolla

Fig. 18: Locating Bolts For Removal Of Upper Radiator Supports Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. h. Remove the radiator assembly. i. Remove the 2 lower radiator supports. 4. Remove electric cooling fan from radiator. Remove the 5 bolts and cooling fan assembly. DISASSEMBLY 1. Remove drain plug. a. Remove the drain plug. b. Remove the O-ring. 2. DENSO Made: Assemble SST. SST 09230-01010 a. Install the claw to the overhaul handle, inserting it in the hole in part "A" as shown in Fig. 19 .

2002 ENGINE Cooling System (Mechanical) - Corolla

Fig. 19: Assembling SST Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. While gripping the handle, adjust the stopper bolts so that dimension "B" shown in Fig. 19 is 0.2 - 0.3 mm (0.008 - 0.012 in.). CAUTION: If this adjustment is not done the claw may be damaged. 3. DENSO Made: Uncaulk lock plates. Using SST to release the caulking, squeeze the handle until stopped by the stopper bolts.

2002 ENGINE Cooling System (Mechanical) - Corolla

Fig. 20: Releasing Caulking With SST Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. SST 09230-01010 4. DENSO Made: Remove tanks and O-rings Lightly tap the bracket of the radiator (or radiator inlet or outlet) with a soft-faced hammer, and remove the tank and the O-ring.

2002 ENGINE Cooling System (Mechanical) - Corolla

Fig. 21: Removing Tank And O-Ring With A Hammer Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 5. A/T (DENSO Made): Remove oil cooler from lower tank. a. Remove the 2 nuts and 2 plate washers.

2002 ENGINE Cooling System (Mechanical) - Corolla

Fig. 22: Locating Nuts For Removal Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the oil cooler and 2 O-rings. INSPECTION
DENSO Made: Inspect Lock Plate For Damage

2002 ENGINE Cooling System (Mechanical) - Corolla

Fig. 23: Inspecting Lock Plate for Damage Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

If the sides of the lock plate groove are deformed, reassembly of the tank will be impossible. Therefore, first correct any deformation with pliers or similar object. Water leakage will result if the bottom of the lock plate groove is damaged.

CAUTION: The radiator can only be recaulked 2 times. After the 2nd time, the radiator core must be replaced. REASSEMBLY 1. A/T (DENSO Made): Install oil cooler to lower tank. a. Install 2 new O-rings to the oil cooler.

2002 ENGINE Cooling System (Mechanical) - Corolla

Fig. 24: Installing New O-Rings Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Install the oil cooler to the lower tank. c. Install the 2 plate washers and 2 nuts. Torque: 8.34 N.m (85 kgf.cm, 74 in..lbf) 2. DENSO Made: Install new O-rings and tanks. a. After checking that there are no foreign objects in the lock plate groove, install the new O-ring without twisting it.

2002 ENGINE Cooling System (Mechanical) - Corolla

Fig. 25: Confirming That O-Ring Is Not Twisted Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE: When cleaning the lock plate groove, lightly rub it with sand paper without scratching it.

b. Install the tank without damaging the O-ring. c. Tap the lock plate with a soft-faced hammer so that there is no gap between it and the tank.

2002 ENGINE Cooling System (Mechanical) - Corolla

Fig. 26: Tapping Lock Plate With Hammer Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 3. DENSO Made: Assemble SST. SST 09230-01010, 09231-14010 a. Install the punch assembly to the overhaul handle, inserting it in the hole in part "A" as shown in Fig. 27 .

2002 ENGINE Cooling System (Mechanical) - Corolla

Fig. 27: Assembling SST Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. While gripping the handle, adjust the stopper bolt so that dimension "B" is as shown in Fig. 27 . Dimension: 8.4 mm (0.331 in.) 4. DENSO Made: Caulk lock plate. a. Lightly press SST against the lock plate in the order shown in the illustration. After repeating this a few times, stopped by the stopped plate.

2002 ENGINE Cooling System (Mechanical) - Corolla

Fig. 28: Caulking Lock Plate Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. SST 09230-01010 NOTE:

Do not stake the areas protruding around the pipes, brackets or tank

2002 ENGINE Cooling System (Mechanical) - Corolla

Fig. 29: Identifying Areas Not To Stake Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

The points shown in Fig. 30 cannot be staked with SST. Wrap vinyl t around the tip of a pair pliers or similar object and be careful not to damage the core plates.

2002 ENGINE Cooling System (Mechanical) - Corolla

Fig. 30: Using Pliers To Stake Ends Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Check the lock plate height (H) after completing the caulking.

2002 ENGINE Cooling System (Mechanical) - Corolla

Fig. 31: Checking Plate Height After Caulking Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Plate height (H): 7.40 - 7.80 mm (0.2913 - 0.3071 in.) If not within the specified height, adjust the stopper bolt of the handle again and caulk again. 5. Install drain plug. a. Install a new O-ring to the drain plug. b. Install the drain plug. 6. Inspect for water leaks. a. Tighten the drain plug. b. Plug the inlet and outlet pipes of the radiator with SST.

2002 ENGINE Cooling System (Mechanical) - Corolla

Fig. 32: Plugging Inlet & Outlet Pipes With SST Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. SST 09230-01010 c. Using a radiator cap tester, apply pressure to the radiator. Test pressure: 177 kPa (1.8 kgf/cm2 , 26 psi) d. Submerge the radiator in water. e. Inspect for leaks.

2002 ENGINE Cooling System (Mechanical) - Corolla

Fig. 33: Inspecting For Leaks Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE: On radiators with resin tanks, there is a clearance between the tank and lock plate where a minute amount of air will remain, giving the appearance of an air leak when the radiator is submerged in water. therefore, before doing the water leak test, first swish the radiator around in the water until all bubbles disappear.

INSTALLATION 1. Install electric cooling fan to radiator. Install the cooling fan with the 5 bolts. Torque: 6 N.m (60 kgf.cm, 53 in..lbf) 2. Install radiator assembly. a. Install the 2 lower radiator supports to the radiator. b. Attach the 2 lower radiator supports on the radiator to the body brackets. c. Install the 2 upper radiator supports with the 2 bolts. Torque: 13 N.m (130 kgf.cm, 9 ft.lbf)

2002 ENGINE Cooling System (Mechanical) - Corolla

NOTE:

After installation, check that the rubber cushion (A), in Fig. 34 , of the support is not depressed.

Fig. 34: Identifying Rubber Cushion Of Radiator Supports Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. d. w/ A/C: Install the A/C condenser with the 4 bolts. e. f. g. h. Connect the upper radiator hose. Connect the lower radiator hose. Connect the radiator reservoir hose. A/T: Connect the 2 oil cooler hoses to oil cooler pipes. i. Connect the No. 1 electric cooling fan connector. j. Connect the No. 2 electric cooling fan connector. 3. Install engine under covers. 4. Fill with engine coolant. 5. Start engine and check for coolant leaks.

2002 ENGINE Cooling System (Mechanical) - Corolla

SPECIFICATIONS
TORQUE SPECIFICATIONS TORQUE SPECIFICATIONS Application Drain Plug At Engine Coolant Drain Union On Cylinder Block Water Pump At Cylinder Block Radiator Support At Body ECT Switch At Cylinder Head Water Pump At Timing Chain Cover Water Inlet At Cylinder Block Electric Cooling Fan At Radiator Fan Motor At Fan Shroud With A/C Without A/C Fan At Fan Motor

Ft. Lbs. (N.m) 9 (12.7) 8 (11) 9 (13) 25 (34) INCH Lbs. (N.m) 80 (9) 80 (9) 53 (6) 23 (2.65) 35 (3.98) 5735 (6.43)

2002 ENGINE COOLING Specifications & Drive Belt Routing

2002 ENGINE COOLING Specifications & Drive Belt Routing

COOLING SYSTEM BLEEDING

NOTE: Whenever cooling system is drained on Celica, special cooling system bleeding procedure needs to be followed. No special procedure is required for any other models.

CELICA NOTE: The following procedure assumes that cooling system has been completely drained by loosening radiator drain plug on bottom of radiator, and engine drain plug on the coolant drain union located on left rear of cylinder block.

1. Remove upper front fender apron cover and upper radiator support cover to access radiator coolant reservoir tank and hoses. Loosen 2 coolant reservoir bolts and 3 reservoir hose retaining clamps. Raise coolant reservoir and place on top of air cleaner cover. Support reservoir from above with wire to prevent reservoir from falling. 2. Remove cooling system bleed plug. Ensure radiator drain plug and engine drain plug on coolant drain union are closed. Add approximately 4 qts. (3.7L) of 50/50 mix of water (preferably distilled water) and coolant to reservoir tank. DO NOT use plain water or alcohol base coolant. Continue to add water/coolant mixture as necessary. If cooling system does not require approximate refill capacity to maintain coolant in reservoir at the FULL mark, air exists in system or system was not properly drained. See 4-CYLINDER COOLING SYSTEM SPECIFICATIONS table. 3. If cooling system will not take additional coolant, squeeze lower radiator hose while blocking off bleed plug opening with finger. Continue to do this while slowly adding coolant. Start engine with reservoir cap and bleed plug removed. Ensure A/C switch is in OFF position, if equipped. Run engine until cooling fan comes on and goes off one time. Add additional coolant to reservoir as necessary. 4. Install bleed plug and reservoir cap. Rotate reservoir cap 2 1/2 turns until click is heard. Increase engine speed to 3000 RPM for 5 seconds, and then allow to idle for 5 seconds. Repeat this procedure for at least 15 minutes. Turn off engine and allow engine to cool completely. With engine completely cooled, coolant level in reservoir should be between LOW and FULL marks. Next time engine warms to normal operating temperature, coolant reservoir level should be above the FULL mark. 5. Reinstall engine coolant reservoir. Reinstall covers. Check for coolant leaks.

DRIVE BELT ROUTING

Automatic belt tension is used to provide proper tension on serpentine drive belt. For serpentine drive belt routing, see Fig. 1 -Fig. 3 .

2002 ENGINE COOLING Specifications & Drive Belt Routing

Fig. 1: Drive Belt Routing (Camry 2.4L 4-Cyl., Camry Solara 2.4L 4-Cyl. & Highlander 2.4L 4-Cyl.) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 ENGINE COOLING Specifications & Drive Belt Routing

Fig. 2: Drive Belt Routing (Celica, Corolla, MR2 & RAV4) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 ENGINE COOLING Specifications & Drive Belt Routing

Fig. 3: Drive Belt Routing (Land Cruiser, Sequoia & Tundra 4.7L V8) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

SPECIFICATIONS
BELT ADJUSTMENT Ensure all drive belts are adjusted to proper tension. See appropriate BELT ADJUSTMENT table. On models with an automatic belt tensioner, no adjustment is necessary, but serpentine drive belt must be properly installed. 4-CYLINDER BELT ADJUSTMENT - Tension In Lbs. (kg) Using Belt Tension Gauge Application Camry & Camry Solara Drive Belt Celica & Corolla Drive Belt ECHO A/C Generator Power Steering Highlander & MR2 Drive Belt Prius A/C Water Pump RAV4 Drive Belt Tacoma A/C Generator Power Steering (1) Used belt is a belt in operation at least 5 minutes. New Belt
(2) (2) (1) Used Belt (2) (2)

110-154 (50-70) 121-143 (55-65) 100-121 (45-55)

(2)

77-100 (35-45) 55-88 (25-40) 55-77 (25-35)

(2)

99-121 (44-55) 99-121 (44-55)

(2)

57-77 (26-35) 57-77 (26-35)

(2)

135-185 (61-84) 116-169 (53-76) 135-180 (61-82)

80-120 (36-54) 66-88 (30-40) 85-120 (39-54)

(2) Automatic belt tensioner is used. Adjustment is not required.

V6 BELT ADJUSTMENT - Tension In Lbs. (kg) Using Belt Tension Gauge Application Avalon A/C Generator Power Steering Camry A/C New Belt 143-187 (65-85) 170-180 (77-82) 120-185 (54-84) 138-192 (63-87)
(1) Used Belt

66-110 (30-50) 95-135 (43-61) 95-135 (43-61) 66-110 (30-50)

2002 ENGINE COOLING Specifications & Drive Belt Routing

Generator Power Steering Camry Solara A/C Generator Power Steering Highlander A/C Generator Power Steering Sienna A/C Generator Power Steering Tacoma & 4Runner A/C Generator Power Steering Tundra A/C Generator Power Steering (1) Used belt is a belt in operation at least 5 minutes.

138-192 (63-87) 146-190 (66-86) 138-192 (63-87) 170-180 (77-82) 150-185 (68-84) 138-192 (63-87) 138-192 (63-87) 146-190 (66-86) 138-192 (63-87) 170-180 (77-82) 150-185 (68-84) 135-185 (61-84) 140-180 (64-82) 135-180 (61-82) 135-185 (61-84) 135-185 (61-84) 135-180 (61-82)

66-110 (30-50) 73-117 (33-53) 99-121 (44-55) 95-135 (43-61) 95-135 (43-61) 66-110 (30-50) 66-110 (30-50) 73-117 (33-53) 66-110 (30-50) 95-135 (43-61) 95-135 (43-61) 80-120 (36-54) 80-120 (36-54) 85-120 (39-54) 80-120 (36-54) 80-120 (36-54) 85-120 (39-54)

V8 BELT ADJUSTMENT - Tension In Lbs. (kg) Using Belt Tension Gauge Application Land Cruiser, Sequoia & Tundra Drive Belt
(1) Used belt is a belt in operation at least 5 minutes. (2) Automatic belt tensioner is used. Adjustment is not required. Belt must be replaced if arrow mark

New Belt
(2)

(1) Used Belt (2)

on automatic belt tensioner is not within area "A". See Fig. 4 .

2002 ENGINE COOLING Specifications & Drive Belt Routing

Fig. 4: Locating Arrow Mark On Automatic Belt Tensioner (Land Cruiser, Sequoia & Tundra 4.7L) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. COOLING SYSTEM SPECIFICATIONS 4-CYLINDER COOLING SYSTEM SPECIFICATIONS Application Coolant Replacement Interval Coolant Capacity Camry & Camry Solara Celica 1ZZ-FE A/T M/T 2ZZ-GE A/T M/T

Specification 30,000 Miles Or 24 Months 6.6 Qts. (6.2L)

5.9 Qts. (5.6L) 6.0 Qts. (5.7L) 6.1 Qts. (5.8L) 6.2 Qts. (5.9L)

2002 ENGINE COOLING Specifications & Drive Belt Routing

Corolla A/T M/T ECHO A/T M/T Highlander MR2 Prius RAV4 A/T M/T Tacoma 2WD PreRunner A/T M/T Except PreRunner A/T M/T 4WD A/T M/T 4Runner With Rear Heater Without Rear Heater Pressure Cap Standard Opening Pressure Camry & Highlander Camry Solara, Corolla, Prius & Tacoma Celica, ECHO, MR2 & RAV4 Thermostat Opening Temperature Camry, Camry Solara, Celica, ECHO, Highlander, MR2, Prius, RAV4 & Tacoma Corolla
(1) Minimum opening pressure is 11.2 psi (.78 kg/cm2 ). (2) Minimum opening pressure is 8.5 psi (.59 kg/cm2 ). (3) Minimum opening pressure is 11.5 psi (.80 kg/cm2 ).

6.0 Qts. (5.7L) 6.1 Qts. (5.8L) 4.5 Qts. (4.3L) 4.7 Qts. (4.4L) 6.8 Qts. (6.4L) 11.0 Qts. (10.4L) 5.2 Qts. (4.9L) 6.6 Qts. (6.2L) 6.7 Qts. (6.3L)

8.7 Qts. (8.2L) 8.8 Qts. (8.3L) 8.2 Qts. (7.8L) 8.5 Qts. (8.0L) 8.7 Qts. (8.2L) 8.8 Qts. (8.3L) 9.5 Qts. (9.0L) 8.5 Qts. (8.0L)
(1) 13.4-17.6 psi (.95-1.25 kg/cm2 ) (2) 10.7-14.9 psi (.75-1.05 kg/cm2 ) (3) 13.5-17.8 psi (.96-1.25 kg/cm2 )

176-183F (80-84C) 165-173F (74-78C)

V6 COOLING SYSTEM SPECIFICATIONS Application Coolant Replacement Interval Coolant Capacity

Specification 30,000 Miles Or 24 Months

2002 ENGINE COOLING Specifications & Drive Belt Routing

Avalon Camry & Camry Solara Highlander Sienna Tacoma 2WD PreRunner A/T M/T Except PreRunner 4WD A/T M/T Tundra 4Runner With Rear Heater Without Rear Heater Pressure Cap Standard Opening Pressure Avalon, Camry, Camry Solara & Sienna Highlander Tacoma & 4Runner Thermostat Opening Temperature
(1) Minimum opening pressure is 10.0 psi (.70 kg/cm2 ). (2) Minimum opening pressure is 11.2 psi (.78 kg/cm2 ). (3) Minimum opening pressure is 8.8 psi (.62 kg/cm2 ).

9.5 Qts. (9.0L) 9.7 Qts. (9.2L) 9.9 Qts. (9.4L) 11.0 Qts. (10.4L)

10.5 Qts. (10.0L) 10.7 Qts. (10.1L) 10.3 Qts. (9.7 L) 10.5 Qts. (9.9L) 10.7 Qts. (10.1L) 10.5 Qts. (9.9L) 9.5 Qts. (9.0L) 8.5 Qts. (8.0L)
(1) 12.1-16.4 psi (.85-1.15 kg/cm2 ) (2) 13.4-17.8 psi (.95-1.25 kg/cm2 ) (3) 10.7-14.9 psi (.75-1.05 kg/cm2 )

176-183F (80-84C)

V8 COOLING SYSTEM SPECIFICATIONS Application Coolant Replacement Interval Coolant Capacity Land Cruiser With Front Heater Only With Front & Rear Heater Sequoia With Front Heater Only With Front & Rear Heater Tundra Pressure Cap Standard Opening Pressure Land Cruiser Sequoia & Tundra

Specification 30,000 Miles Or 24 Months

15.5 Qts. (14.7L) 16.3 Qts. (15.4L) 12.4 Qts. (11.7L) 14.1 Qts. (13.4L) 12.3 Qts. (11.6L)
(1) 13.4-17.8 psi (.95-1.25

kg/cm2 )
(2) 10.7-14.9 psi (.75-1.05

kg/cm2 )

2002 ENGINE COOLING Specifications & Drive Belt Routing

Thermostat Opening Temperature

(1) Minimum opening pressure is 11.4 psi (.80 kg/cm2 ). (2) Minimum opening pressure is 8.6 psi (.60 kg/cm2 ).

176-183F (80-84C)

2002 ENGINES Exhaust System - Corolla

2002 ENGINES Exhaust System - Corolla

EXHAUST SYSTEM
COMPONENTS

Fig. 1: Identifying Exhaust System Components Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REPLACEMENT

2002 ENGINES Exhaust System - Corolla

1. Combination of center pipe : The combination of the re-using, re-newing parts and joint portion are as follows:

Fig. 2: Exhaust System Component Replacement Chart Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. WARNING: Be sure to remove the burr at the cutting portion.

2002 ENGINES Exhaust System - Corolla

Fig. 3: Measuring Component Lengths Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 2. Cut of center pipe : When exchanging with the supply part, remove the exhaust pipe from the vehicle and cut it at the measured position shown in the illustration.

2002 ENGINES Exhaust System - Corolla

3. Installation of center pipe and catalytic converter : NOTE: Install exhaust pipe clamp in the middle where the pipes are overlapped.

Fig. 4: Identifying Proper Clamp Installation Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. a. As shown in the illustration, install exhaust pipe clamp and torque it temporary. b. Install it under the condition of step 3( ) and confirm that there is no friction between each support bracket and the body. then, torque exhaust pipe clamp. Torque: 68 N.m (700 kgf.cm, 50 ft.lbf) .

2002 ENGINE Lubrication - Corolla

2002 ENGINE Lubrication - Corolla

OIL AND FILTER

INSPECTION 1. Check engine oil quality. Check the oil for deterioration, entry of water, discoloring or thinning. If the quality is visibly poor, replace the oil. Oil grade: API grade SJ, Energy-Conserving or ILSAC multi-grade engine oil. SAE 5W-30 is the best choice for your vehicle, for good fuel economy, and good starting in cold weather.

Fig. 1: Displaying Recommended Oil Viscosity Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 2. Check engine oil level. 5 minutes after warming up the engine, the oil level should be between the "L" and "F" marks on the dipstick. If low, check for leakage and add oil up to the "F" mark. NOTE: Do not fill with engine oil above the "F" mark.

3. Remove oil pressure switch, and install oil pressure gauge. a. Remove the oil pressure switch.

2002 ENGINE Lubrication - Corolla

b. Install the oil pressure gauge.

Fig. 2: Installing Oil Pressure Gauge Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 4. Warm up engine. Allow the engine to warm up to normal operating temperature. 5. Check oil pressure. Oil pressure:

Fig. 3: Displaying Oil Pressure Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 6. Remove oil pressure gauge and reinstall oil pressure switch. a. Remove the oil pressure gauge.

2002 ENGINE Lubrication - Corolla

b. Apply adhesive to 2 or 3 threads of the oil pressure switch.

Fig. 4: Applying Adhesive To Oil Pressure Switch Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Adhesive: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent c. Install the oil pressure switch. Torque: 13 N.m (130 kgf.cm, 9 ft.lbf) 7. Start engine and check for leaks. REPLACEMENT CAUTION:

Prolonged and repeated contact with mineral oil will result in the removal of natural fats from the skin, leading to dryness, irritation and dermatitis. In addition, used engine oil contains potentially harmful contaminants which may cause skin cancer. Exercise caution in order to minimize the length and frequency of contact of your skin to used oil. Wear protective clothing and gloves. Wash your skin thoroughly with soap and water, or use water-less hand cleaner, to remove any used engine oil. Do not use gasoline, thinners, or solvents. In order to preserve the environment, used oil and used oil filter must be disposed of only at designated disposal sites.

1. Drain engine oil.

2002 ENGINE Lubrication - Corolla

a. Remove the oil filter cap. b. Remove the drain plug, and drain the oil into a container. 2. Replace oil filter. a. Using SST, remove the oil filter.

Fig. 5: Removing Oil Filter With SST Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. SST 09228-06501 Check and clean the oil filter installation surface. Check the part number of the new oil filter is as same as old one. Apply clean engine oil to the gasket of a new oil filter. Lightly screw the oil filter into place, and tighten it until the gasket contacts the seat. Using SST, tighten it an additional 3/4 turn.

b. c. d. e. f.

2002 ENGINE Lubrication - Corolla

Fig. 6: Tightening Oil Filter With SST Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. SST 09228-06501 3. Refill with engine oil. a. Clean and install the oil drain plug with a new gasket. Torque: 37 N.m (378 kgf.cm, 27 ft.lbf) b. Fill with fresh engine oil. Capacity:

Fig. 7: Displaying Oil Capacity Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Install the oil filter cap. 4. Start engine and check for oil leaks. 5. Recheck engine oil level.

2002 ENGINE Lubrication - Corolla

OIL PUMP
COMPONENTS

Fig. 8: Identifying Oil Pump Components (1 Of 3) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 ENGINE Lubrication - Corolla

Fig. 9: Identifying Oil Pump Components (2 Of 3) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 ENGINE Lubrication - Corolla

Fig. 10: Identifying Oil Pump Components (3 Of 3) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL 1. Drain engine oil. 2. Remove timing chain and crankshaft timing sprocket. See step 19) under REMOVAL under TIMING CHAIN. 3. Remove oil pump. Remove the 5 bolts, oil pump and gasket.

2002 ENGINE Lubrication - Corolla

Fig. 11: Locating Bolts For Removal Of Oil Pump & Gasket Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. DISASSEMBLY 1. Remove relief valve. Remove the plug, spring and relief valve. 2. Remove drive and driven rotors. Remove the 3 screws, pump body cover, the drive and driven rotors. INSPECTION 1. Inspect oil jet. Check the oil jet for damage or clogging. If necessary, replace the oil pump assembly.

2002 ENGINE Lubrication - Corolla

Fig. 12: Checking Oil Jet For Clogging Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 2. Inspect relief valve. Coat the valve with engine oil and check that it falls smoothly into the valve hole by its own weight.

2002 ENGINE Lubrication - Corolla

Fig. 13: Checking Relief Valve Falls Smoothly Into Valve Hole Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. If it does not, replace the relief valve. If necessary, replace the oil pump assembly. 3. Inspect rotor side clearance. a. Inspect the rotors for the side clearance. Using a feeler gauge and precision straight edge, measure the clearance between the rotors and precision straight edge.

2002 ENGINE Lubrication - Corolla

Fig. 14: Measuring Clearance Between Rotors & Precision Straight Edge Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Standard side clearance: 0.025 - 0.075 mm (0.0010 - 0.0030 in.) Maximum side clearance: 0.15 mm (0.0059 in.) If the side clearance is greater than maximum, replace the rotors as a set. If necessary, replace the oil pump assembly. b. Inspect the rotors for the tip clearance. Using a feeler gauge, measure the clearance between the drive and driven rotor tips.

2002 ENGINE Lubrication - Corolla

Fig. 15: Measuring Clearance Between Drive & Driven Rotor Tips Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Standard tip clearance: 0.060 - 0.180 mm (0.0024 - 0.0071 in.) Maximum tip clearance: 0.35 mm (0.0138 in.) If the tip clearance is greater than maximum, replace the rotors as a set. c. Inspect the rotor for the body clearance. Using a feeler gauge, measure the clearance between the driven rotor and body.

2002 ENGINE Lubrication - Corolla

Fig. 16: Measuring Clearance Between Driven Rotor & Body Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Standard body clearance: 0.100 - 0.180 mm (0.0039 - 0.0071 in.) Maximum body clearance: 0.30 mm (0.0118 in.) If the body clearance is greater than maximum, replace the rotors as a set. If necessary, replace the oil pump assembly. REASSEMBLY 1. Install drive and driven rotors a. Place the drive and driven rotors into pump body with the marks facing the pump body cover side.

2002 ENGINE Lubrication - Corolla

Fig. 17: Placing Drive & Driven Rotors With Marks Facing Pump Body Cover Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Install the pump body cover with the 3 screws. Torque: 10.5 N.m (107 kgf.cm, 8 ft.lbf) . 2. Install relief valve. Insert the relief valve and spring into the pump body hole, and install the plug. Torque: 37 N.m (375 kgf.cm, 27 ft.lbf) INSTALLATION 1. Install oil pump. a. Place a new gasket on the cylinder block. b. Engage the spline teeth of the oil pump drive rotor with the large teeth of the crankshaft, and slide the oil pump.

2002 ENGINE Lubrication - Corolla

Fig. 18: Engage Teeth Of Oil Pump Drive Rotor & Crankshaft & Slide Oil Pump Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Install the oil pump with the 5 bolts. Torque: 9 N.m (92 kgf.cm, 80 in..lbf) Install crankshaft timing sprocket and timing chain. See step 4) under INSTALLATION under TIMING CHAIN. Fill engine with oil. Start engine and check for leaks. Recheck engine oil level.

2. 3. 4. 5.

SPECIFICATIONS
SERVICE DATA SERVICE DATA Application Oil Pressure At Idle Speed At 3,000 rpm Oil Pump Side Clearance

Specification 29 kPa )0.3 kgf/cm2, 43 psi) Or More 294-539 kPa (3.0-5.5 kgf/cm2, 43-78 psi)

2002 ENGINE Lubrication - Corolla

STD Maximum Body Clearance STD Maximum Tip Clearance STD Maximum TORQUE SPECIFICATIONS TORQUE SPECIFICATIONS Application Oil Pressure Switch At Bearing Cap Subassembly Drain Plug At Oil Pan Plug At Oil Pump Body Oil Pump Body Cover At Oil Pump Body Oil Pump At Cylinder Block

0.025-0.075mm (0.0010-0.0030 in.) 0.15mm (0.0059 in.) 0.100-0.180mm (0.0039-0.0071 in.) 0.30mm (0.0118 in.) 0.06-0.180mm (0.0024-0.0071 in.) 0.35mm (0.0138 in.)

Ft. Lbs. (N.m) 9 (13) 27 (36.7) 27 (37) 8 (10.5) INCH Lbs. (N.m) 80 (9)

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

ENGINE IDENTIFICATION
Engine serial number is stamped on rear of cylinder block. See Fig. 1. ENGINE IDENTIFICATION CODES Engine 1.8L 4-Cylinder

Code 1ZZ-FE

Fig. 1: Locating Engine Serial Number Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

CO/HC
INSPECTION

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

NOTE:

This check is used only to determine whether or not the idle CO/HC complies with regulations.

1. Install Conditions. a. Engine at normal operating temperature. b. Air cleaner installed. c. Air pipes and hoses of air induction system connected. d. All accessories switched OFF. e. All vacuum lines properly connected. f. SFI system wiring connectors fully plugged. g. Ignition timing check correctly. h. Transmission in neutral position. i. Tachometer and CO/HC meter calibrated by hand. 2. Start Engine. 3. Race Engine At 2,500 RPM For Approximately 180 Seconds. 4. Insert CO/HC Meter Testing Probe At Least 40 CM (1.3 ft) Into Tailpipe During Idling. NOTE: When doing the 2 mode (idle and 2,500 rpm) test, these measurement order prescribed by the applicable local regulations.

5. Immediately Check CO/HC Concentration At Idle And/Or 2,500 RPM. Complete the measuring with 3 minutes. If the CO/HC concentration does not comply with regulations, troubleshoot in the order given below. Check the Heated Oxygen Sensor operation. See the table below for possible causes, and then inspect and correct the applicable causes if necessary.

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Fig. 2: Troubleshooting CO/HC Concentration Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

COMPRESSION
INSPECTION NOTE: If there is lack of power, excessive oil consumption or poor fuel economy, measure the compression pressure.

1. 2. 3. 4.

Warm Engine Up To Normal Operating Temperature And Stop Engine. Remove Ignition Coils . Remove Spark Plugs . Inspect Cylinder Compression Pressure. : a. Insert a compression gauge into the spark plug hole. NOTE: Always use a fully charged battery to obtain engine speed of 250 rpm or more.

b. Fully open the throttle. NOTE: This measurement must be done in as short a time as possible.

c. While cranking the engine, measure the compression pressure. d. Repeat steps () through (b) for each cylinder.

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Fig. 3: Testing Cylinder Compression Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Compression pressure: 1,500 kPa (15.3 kgf/cm2 , 218 psi) . Minimum pressure: 1,000 kPa (10.2 kgf/cm2 , 145 psi) . Difference between each cylinder: 100 kPa (1.0 kgf/cm2 , 15 psi) or less . e. If the cylinder compression in one more cylinders is low, pour a small amount of engine oil into the cylinder through the spark plug hole and repeat steps () through (b) for cylinders with low compression. If adding oil helps the compression, it is likely that the piston rings and/or cylinder bore are worn or damaged. If pressure stays low, a valve may be sticking or seating is improper, or there may be leakage past the gasket. 5. Reinstall Spark Plugs . 6. Reinstall Ignition Coils .

VALVE CLEARANCE
ADJUSTMENT NOTE: Inspect and adjust the valve clearance when the engine is cold.

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

1. Remove Cylinder Head Cover. See REMOVAL under TIMING CHAIN. 2. Set No. 1 Cylinder To TDC/compression. a. Turn the crankshaft pulley, and align its groove with the timing mark "0" of the timing chain cover.

Fig. 4: Locating Timing Mark Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Check that the point marks of the camshaft timing sprockets are in straight line on the timing chain cover surface as shown in the illustration.

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Fig. 5: Locating Camshaft Point Marks Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. If not, turn the crankshaft 1 revolution (360) and align the marks as above. 3. Inspect Valve Clearance. a. Check only the valves indicated. 1. Using a feeler gauge, measure the clearance between the valve lifter and camshaft.

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Fig. 6: Identifying Valves For Clearance Measurement Step 3(a) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 2. Record the out-of-specification valve clearance measurements. They will be used later to determine the required replacement valve lifter.

Fig. 7: Valve Clearance Chart (Cold) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Turn the crankshaft 1 revolution (360) and align the mark as above (See step 2). c. Check only the valves indicated as shown. For Measurement procedure the valve clearance (See step 3 (a)(1 and 2)).

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Fig. 8: Identifying Valves For Clearance Measurement Step 3(c) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 4. Adjust Valve Clearance. a. Set the No. 1 cylinder to the TDC/compression (See step 2). b. Place matchmarks on the timing chain and camshaft timing sprockets.

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Fig. 9: Matchmarking Timing Chain Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Remove the 2 nuts and chain tensioner.

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Fig. 10: Locating Chain Tensioner Nuts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. d. Remove the camshafts and timing sprocket assemblies. 1. Remove the 19 bolts and 9 camshaft bearing caps. For bolt removal sequence, see step 21, REMOVE CAMSHAFTS in REMOVAL under CYLINDER HEAD. 2. Remove the 2 camshaft and timing sprocket assemblies.

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Fig. 11: Locating Camshaft Bearing Cap Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. CAUTION:

Be careful not to drop anything inside the timing chain cover. Do not allow the chain to come into contact with water or dust.

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Fig. 12: Securing Timing Chain Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. e. Tie the timing chain as shown in the illustration. f. Remove the valve lifter. NOTE: Lifters are available in 35 sizes in increments of 0.020 mm (0.0008 in.), from 5.060 mm (0.1992 in.) to 5.740 mm (0.2260 in.).

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Fig. 14: Valve Lifter Selection Chart (Intake) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Fig. 15: Valve Lifter Selection Chart (Exhaust) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. g. Determine the replacement valve lifter size according to this formula or charts: for charts, see Fig. 14 and Fig. 15 . Using a micrometer, measure the thickness of the removed lifter.

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Fig. 13: Measuring Lifter Thickness Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Calculate the thickness of a new lifter so the valve clearance comes within the specified value. T ... Thickness of used lifter. A ... Measured valve clearance. N ... Thickness of new lifter. Intake: N = T + (A - 0.20 mm (0.008 in.)) . Exhaust: N = T + (A - 0.30 mm (0.012 in.)) . Select a new lifter with a thickness as close as possible to the calculated values. Reinstall the valve lifter. See step 3 in REASSEMBLY under CYLINDER HEAD. Align the crankshaft pulley groove with the timing mark 0 of the timing chain cover. Hold the timing chain, and place the intake camshaft and timing sprocket assembly. Align the matchmarks on the timing chain and camshaft timing sprocket. Reinstall the 2 camshaft and timing sprocket assemblies. See step 1 in INSTALLATION under TIMING CHAIN.

h. i. j. k. l.

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Fig. 16: Installing Sprocket Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. m. Check that the point marks of the camshaft timing sprocket and VVT timing sprocket are in straight line on the timing chain cover surface, as shown in the illustration.

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Fig. 17: Locating Camshaft Point Marks Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. n. Check that the matchmarks on the timing chain and 2 timing sprockets.

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Fig. 18: Inspecting Timing Chain & Sprocket Matchmark Alignment Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. o. Install the chain tensioner. See step 5 in INSTALLATION under TIMING CHAIN. p. Recheck the valve clearance. See step 3. q. Check the valve timing. See step 14 in INSTALLATION under TIMING CHAIN. 5. Reinstall Cylinder Head Cover. See step 15 in INSTALLATION under TIMING CHAIN.

IGNITION TIMING
INSPECTION 1. Allow The Engine To Warm Up To Normal Operating Temperature. 2. Connect TOYOTA Hand-Held Tester Or OBD II Scan Tool. a. Connect the TOYOTA hand-held tester or OBD II scan tool to the DLC3.

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Fig. 19: Locating DLC3 Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Please refer to the TOYOTA hand-held tester or OBD II scan tool operator's for further details. 3. Check Idle Speed. See IDLE SPEED. 4. Connect the tester probe of a timing light to the black-white lead wire of the ignition coil connector for No. 1 cylinder.

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Fig. 20: Identifying Proper Probe Light Setup Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 5. Inspect Ignition Timing. NOTE: After engine rpm is kept at 1,000 - 1,300 rpm for 5 seconds, check that it returns to idle speed.

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Fig. 21: Locating DLC1 Terminals TE1 & E1 Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. a. Using SST, connect terminals TE1 and E1 of the DLC1. SST 09843-18020 b. Using a timing light, check the ignition timing. Ignition timing: 8 - 12 BTDC @ idle . c. Remove the SST from the DLC1. NOTE: The timing mark moves in a range between 6 and 15.

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Fig. 22: Identifying Timing Mark Range Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 6. Further Check Ignition Timing. Ignition timing: 6 - 15 BTDC @ idle . 7. Disconnect Timing Light From Engine. 8. Disconnect TOYOTA Hand-Held Tester Or OBD II Scan Tool.

IDLE SPEED
INSPECTION 1. Initial Conditions. a. Engine at normal operating temperature. b. Air cleaner installed. c. All pipes and hoses of air induction system connected. d. All vacuum lines properly connected. e. SFI system wiring connectors fully plugged. f. All operating accessories switched OFF. g. Ignition timing check correctly.

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

h. Transmission in neutral position. i. A/C switched OFF. 2. Connect TOYOTA Hand-Held Tester Or OBD II Scan Tool. See step 2 in inspection under IGNITION TIMING. 3. Inspect Idle Speed. a. Race the engine at 2,500 rpm for approximately 90 seconds. b. Check the idle speed. Idle speed (with Cooling fan OFF): 700 +/- 50 rpm . If the idle speed is not as specified, check the IAC valve and air intake system. 4. Disconnect TOYOTA Hand-Held Tester Or OBD II Scan Tool.

TIMING CHAIN
COMPONENTS

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Fig. 23: Locating Timing Chain Components (1 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Fig. 24: Locating Timing Chain Components (2 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL 1. Drain Engine Coolant.

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

2. 3. 4. 5. 6.

Remove Washer Tank. Remove RH Front Wheel. Remove RH Engine Under Cover. Remove Drive Belt and Generator . Disconnect PS Pump From Engine. a. Disconnect the PS oil pressure switch connector. b. Using SST, remove the pulley bolt. SST 09960-10010 (09962-01000, 09963-01000) c. Remove the PS pump pulley.

Fig. 25: Removing Power Steering Pump Pulley Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE: Put aside the pump and suspend it to the cowl with a string.

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Fig. 26: Locating Power Steering Pump Mounting Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. d. Remove the 2 nuts and through bolts, and disconnect the PS pump from the engine. 7. Remove RH Engine Mounting Insulator. CAUTION: Place a wooden block or rubber block between a jack and the oil pan.

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Fig. 27: Identifying Proper Jack To Engine Placement Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. a. Set the jack to the engine. b. With A/C: Remove the bolt holding the A/C piping clamp to the RH engine mounting insulator. c. Remove the 4 bolts, 2 nuts and RH engine mounting insulator. 8. Remove Cylinder Head Cover. a. Remove the 2 bolts, 2 clips and No. 2 cylinder head cover. b. Disconnect the ignition coil connectors. c. Remove the 2 bolts and engine wire. d. Remove the 4 bolts and 4 ignition coils.

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Fig. 28: Locating Ignition Coil Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. e. Disconnect the 2 PCV hoses from the cylinder head cover. f. Remove the 9 bolts, 2 seal washers, 2 nuts, cable bracket, cylinder head cover and gasket.

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Fig. 29: Locating Cylinder Head Cover Mounting Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Fig. 30: Locating Timing Mark Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 9. Set No. 1 Cylinder To TDC Compression. a. Turn the crankshaft pulley, and align its groove with the timing mark 0 of the timing chain cover.

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Fig. 31: Aligning Crankshaft Pulley Groove & 0 Timing Mark Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Check that the point marks of the camshaft timing sprocket and VVT timing sprocket are in straight line on the timing chain cover surface as shown in the illustration. If not, turn the crankshaft 1 revolution (360) and align the marks as above.

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Fig. 32: Identifying Correct Camshaft & VVT Timing Sprocket Point Marks Alignment Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 10. Remove Crankshaft Pulley. a. Using SST, remove the pulley bolt. SST 09213-70011, 09330-00021 NOTE: If necessary, remove the pulley with SST. SST 09950-50013 (09951-05010, 09952-05010, 09953-05020, 09954-05021).

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Fig. 33: Removing Crankshaft Pulley Bolt Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Fig. 34: Using SST To Remove Crankshaft Pulley Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the crankshaft pulley. 11. Disconnect Crankshaft Position Sensor From Timing Chain Cover. Remove the 2 bolts and crankshaft position sensor.

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Fig. 35: Locating Crankshaft Position Sensor, Drive Belt Tensioner & Mounting Bracket Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 12. Remove The Bolt, Nut And Drive Belt Tensioner. 13. Remove The 3 Bolts And RH Engine Mounting Bracket. 14. Remove The 2 Nuts And Chain Tensioner.

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Fig. 36: Locating Chain Tensioner Nuts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 15. Remove Water Pump . 16. Remove Timing Chain Cover. a. Remove the 11 bolts and nut.

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Fig. 37: Locating Mounting Bolts & Removing Timing Chain Cover Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Using a torx wrench socket (E8), remove the stud bolt. CAUTION: Be careful not to damage the contact surfaces of the timing chain cover, cylinder head and cylinder block. c. Remove the timing chain cover by prying the portions between the cylinder head and cylinder block with a screwdriver. 17. Remove Crank Angle Sensor Plate. 18. Remove Bolt And Chain Tensioner Slipper. CAUTION: Position shop rags as shown to prevent damage.

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Fig. 38: Prying Crankshaft Timing Sprocket Off Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 19. Remove Timing Chain And Crankshaft Timing Sprocket. If necessary, pry between the timing chain and oil pump by 2 screwdrivers. 20. Remove 2 Bolts And Chain Vibration Damper. 21. Remove Camshaft Timing Sprocket And VVT Timing Sprocket. CAUTION: Be careful not to damage the cylinder head and valve lifter by a wrench. a. Hold the hexagonal head wrench portion of the camshaft with a wrench, and loosen the sprocket. b. Remove the bolt and camshaft timing sprocket. c. Remove the bolt and VVT timing sprocket.

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Fig. 39: Locating VVT & Camshaft Timing Sprocket Mounting Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSPECTION 1. Inspect Timing Chain And Timing Sprockets. NOTE: Make the same measurements pulling at 3 or more places selected at random.

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Fig. 40: Measuring Appropriately Stretched Timing Chain Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. a. Using vernier calipers, measure the length of the 16 links with the chain dully stretched. Maximum chain elongation: 122.6 mm (4.827 in.) . If the elongation is greater than maximum, replace the chain. b. Wrap the chain around the timing sprocket. NOTE: Vernier calipers contact the chain rollers for measuring.

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Fig. 41: Measuring Timing Sprocket Diameter Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 42: Timing Sprocket Diameter Specifications Chart With Chain On Sprocket Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Using vernier calipers, measure the timing sprocket diameter with the chain. If the diameter is less than minimum, replace the chain and sprockets. 2. Inspect Chain Tensioner Slipper And Vibration Damper.

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Measure the chain tensioner slipper and vibration damper wear. Maximum wear: 1.0 mm (0.039 in.) .

Fig. 43: Identifying Vibration Damper Depth Wear Measuring Points Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. If the wear is greater than maximum, replace the slipper and/or damper. 3. Inspect Chain Tensioner. a. Check that the plunger moves smoothly when the ratchet pawl is raised with your finger.

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Fig. 44: Inspecting Chain Tensioner Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Release the ratchet pawl and check that the plunger is locked in place by the ratchet pawl and does not move when pushed with your finger. 4. Inspect Oil Jet . 5. Inspect Drive Belt Tensioner. Check the oil leakage and crack. If necessary, replace the drive belt tensioner. REPLACEMENT
Replace Crankshaft Front Oil Seal

HINT: There are 2 methods (() and (a)) to replace the oil seal. a. If the timing chain cover is removed from the cylinder block. 1. Using a screwdriver and a hammer, tap out the oil seal.

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Fig. 45: Removing Oil Seal Timing Chain Cover Removed Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 2. Using SST and a hammer, tap in a new oil seal until its surface is flush with the timing chain cover edge. SST 09309-37010. 3. Apply MP grease to the oil seal lip.

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Fig. 46: Installing Oil Seal Timing Chain Cover Removed Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. If the timing chain cover is installed to the cylinder block. 1. Using SST, remove the oil seal. SST 09308-10010.

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Fig. 47: Removing Oil Seal Timing Chain Cover Installed Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 2. Using SST and a hammer, tap in a new oil seal until its surface is flush with the timing chain cover edge. SST 09309-37010.

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Fig. 48: Installing Oil Seal Timing Chain Cover Installed Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSTALLATION 1. Install Camshaft Timing Sprocket And VVT Timing Sprocket. a. Align the camshaft knock pin with the knock pin groove on the sprocket side with the timing mark, and slide on the camshaft timing sprocket and VVT timing sprocket.

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Fig. 49: Identifying Camshaft & VVT Timing Sprocket Timing Marks Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Temporarily install the timing sprocket bolt. c. Hold the hexagon wrench head portion of the camshaft with a wrench, and tighten the timing sprocket bolt.Torque: 54 N.m (550 kgf.cm, 40 ft.lbf) .

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Fig. 50: Locating Hexagon Wrench Head Portion Of Camshaft & Timing Sprocket Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 2. Set No. 1 Cylinder To TDC Compression. a. Turn the hexagonal wrench head portion of the camshafts, and align the point marks of the camshaft timing sprockets.

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Fig. 51: Aligning Camshaft Point Marks Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Using a crankshaft pulley bolt, turn the crankshaft and set the set key on the crankshaft upward.

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Fig. 52: Identifying Crankshaft Set Key Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 3. Install Chain Vibration Damper With The 2 Bolts. . Torque: 9 N.m (92 kgf.cm, 80 in..lbf)

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Fig. 53: Locating Chain Vibration Damper Mounting Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 4. Install Timing Chain And Crankshaft Timing Sprocket. NOTE: If necessary, install the sprocket with SST# 09223-22010.

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Fig. 54: Aligning Crankshaft Timing Sprocket & Chain Alignment Marks Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Fig. 55: Identifying SST# 09223-22010 Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. a. Install the timing chain on the crankshaft timing sprocket with the #1 mark link aligned with the timing mark on the crankshaft timing sprocket. b. Install the timing chain on the camshaft timing sprocket and VVT timing sprocket with the #53 and #67 mark links aligned with the timing marks on the camshaft timing sprocket and VVT timing sprocket.

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Fig. 56: Aligning Camshaft Timing Sprocket & VVT Timing Sprocket Timing Marks Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Check that the tension between the VVT timing sprocket and crankshaft timing sprocket. NOTE: Do not turn the crankshaft.

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Fig. 57: Locating Slipper Mounting Bolt & Cylinder Head Stopper Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 5. Install chain tensioner slipper/slipper with the bolt. Torque: 18.5 N.m (189 kgf.cm, 14 ft.lbf). Check that the slipper is held on the cylinder head stopper.

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

6. Install Crank Angle Sensor Plate With The"F" Mark Facing Forward.

Fig. 58: Locating Crank Angle Sensor Plate "F" Mark Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 7. Install Timing Chain Cover And Water Pump. a. Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the timing chain cover, cylinder head and cylinder block. Using a razor blade and a gasket scraper, remove all the old packing (FIPG) material from the gasket surfaces and sealing grooves. Thoroughly clean all components to remove all the loose material. Using a non-residue solvent, clean both sealing surfaces. NOTE:

Avoid applying an excessive amount to the surface. Install a nozzle that has been cut to a 4 - 5 mm (0.16 - 0.20 in.) opening. Parts must be assembled within 3 minutes of application. Otherwise the material must be removed and reapplied. Immediately remove nozzle from the tube and reinstall cap.

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Fig. 59: Identifying Legend Locations For Seal Packing Application Positions Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Fig. 60: Seal packing Legend & Position Specifications Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Apply seal packing to the timing chain cover as shown in the illustration.Seal packing: Part No. 08826-00100 or equivalent . NOTE:

Install a nozzle that has been cut to a 4 - 5 mm (0.16 - 0.20 in.) opening. Avoid applying an excessive amount to the surface. Parts must be assembled within 3 minutes of application. Otherwise the material must be removed and reapplied. Immediately remove nozzle from the tube and reinstall cap.

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Fig. 61: Identifying Seal Packing Application Positions Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Apply seal packing to 2 locations as shown in the illustration.Seal packing: Part No. 0882600080 or equivalent . NOTE:

Pay attention not to wrap the chain and slipper over the chain cover seal line. After installing the chain cover, must install the mounting bracket and water pump within 15 minutes.

d. Install the timing chain cover, O-ring and water pump with the 17 bolts and nut in locations called out in Fig. 62. Uniformly tighten the bolts and nut in several passes. Torque: 9 N.m (92 kgf.cm, 80 in..lbf) for 10 mm head (C) . 13 N.m (133 kgf.cm, 10 in..lbf) for 10 mm head (A) . 11 N.m (113 kgf.cm, 8 ft.lbf) for 10 mm head (others) . 18.5 N.m (189 kgf.cm, 14 ft.lbf) for 12 mm head .

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Each bolt length in indicated in the illustration. Bolt "A" 45 mm (1.77 in.). Bolt "B" 35 mm (1.38 in.). Bolt "C" 30 mm (1.18 in.). Bolt "D" 25 mm (0.98 in.).

Fig. 62: Identifying Bolt Locations Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. e. Using a torx wench socket (E8), install the stud bolt. Torque: 9.3 N.m (95 kgf.cm, 82 in..lbf) . 8. Install RH Engine Mounting Bracket.

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

NOTE:

Do not apply seal packing to 2 or 3 threads of the bolt end.

Fig. 63: Locating Crankshaft Position Sensor, Drive Belt Tensioner & Mounting Bracket Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. a. Apply seal packing to threads of the mounting bolt. Seal packing: Part No. 08826-00080 or equivalent . b. Install the mounting bracket with the 3 bolts. Torque: 47 N.m (479 kgf.cm, 35 ft.lbf) . 9. Install Drive Belt Tensioner. a. Install the drive belt tensioner with the bolt and nut. Torque: 69 N.m (704 kgf.cm, 51 ft.lbf) for bolt . 29 N.m (296 kgf.cm, 21 ft.lbf) for nut .

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

NOTE:

Take 3 seconds or more for 1 full stroke.

b. Hook the tool on the hexagonal portion of the drive belt tensioner bracket and operate drive belt tensioner 3 times with full stroke. 10. Install Crankshaft Position Sensor. Torque: 9 N.m (92 kgf.cm, 80 in..lbf). 11. Install Crankshaft Pulley. a. Clean the crankshaft pulley inside. b. Align the pulley set key with the key groove of the pulley, and slide on the pulley. c. Using SST, install the pulley bolt.Torque: 138 N.m (1,409 kgf.cm, 102 ft.lbf) . SST 0921370011, 09330-00021.

Fig. 64: Installing Crankshaft Pulley Bolt Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 12. Install Chain Tensioner. a. Check the chain tensioner. See 2 in INSPECTION under TIMING CHAIN.

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

b. Release the ratchet pawl, fully push in the plunger and apply the hook to the pin so that the plunger cannot spring out.

Fig. 65: Locating Chain Tensioner Hook & Pin Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

In case that the hook is released while pushing in, apply the hook again and push the tensioner in. Pay attention not to catch the O-ring as it is built in the chain tensioner previously.

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Fig. 66: Installing Chain Tensioner Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Push the chain tensioner into the timing chain cover, and install the 2 nuts.Torque: 9 N.m (92 kgf.cm, 80 in..lbf) . 13. Set Chain Tension. a. Turn the crankshaft counterclockwise, and disconnect the plunger knock pin from the hook.

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Fig. 67: Confirming Chain Tension (1 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE: If the plunger does not spring out, press the slipper into the chain tensioner with a screwdriver or your finger so that the hook is released from the knock pin and the plunger springs out.

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Fig. 68: Confirming Chain Tensioner Plunger Position Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Fig. 69: Confirming Chain Tension (2 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Turn the crankshaft clockwise, and check that the slipper is pushed by the plunger. 14. Check Valve Timing. CAUTION: Always turn the crankshaft clockwise.

a. Turn the crankshaft pulley, and align its groove with timing mark 0 of the timing chain cover. b. Check that the point marks of the camshaft timing sprockets are in straight line on the timing chain cover surface as shown in the illustration.

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Fig. 70: Identifying Correct Camshaft & VVT Timing Sprocket Point Marks Alignment Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. If not, turn the crankshaft 1 revolution (360) and align the marks as above. 15. Install Cylinder Head Cover. a. Remove any old packing (FIPG) material. NOTE: Part must be assembled within 3 minutes of application. Otherwise the material must be remove and reapplied.

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Fig. 71: Identifying Seal Packing Application Points Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Apply seal packing to 2 locations as shown in the illustration. Seal packing: Part No. 0882600080 or equivalent . c. Install the gasket to the cylinder head cover. If the gasket has damage, replace a new one. d. Install the cylinder head cover and cable bracket with the 9 bolts, 2 seal washers and 2 nuts. Uniformly tighten the bolts and nuts, in the several passes, in the sequence shown.

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Fig. 72: Identifying Cylinder Head Cover & Cable Bracket Bolt & Nut Tightening Sequence Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Torque: 11 N.m (113 kgf.cm, 8 ft.lbf) for without washer . 9 N.m (92 kgf.cm, 80 in..lbf) for with washer . e. Connect the 2 PCV hoses to the cylinder head cover. f. Install the 4 ignition coils with 4 bolts. g. Install the engine wire with 2 bolts. h. Connect the ignition coil connectors. i. Install the No. 2 cylinder head cover with 2 nuts and 2 clips. 16. Install RH Engine Mounting Insulator. a. Install the RH engine mounting insulator with the 4 bolts and 2 nuts.

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Fig. 73: Identifying Engine Mounting Insulator Bolt & Nut Placement Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Torque: 63.7 N.m (650 kgf.cm, 47 ft.lbf) for bolt A . 25.5 N.m (260 kgf.cm, 19 ft.lbf) for bolt B . 52.0 N.m (530 kgf.cm, 38 ft.lbf) for nut . b. With A/C: Install the bolt holding the A/C piping clamp to the RH engine mounting insulator. 17. Install PS Pump. a. Install the PS pump with the 2 through bolts and nuts.Torque: 37 N.m (370 kgf.cm, 27 ft.lbf) . b. Install the PS pump pulley with the pulley nut. c. Using SST, torque the pulley nut. Torque: 43 N.m (440 kgf.cm, 32 ft.lbf) . SST 09960-10010 (09962-01000, 09963-01000).

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Fig. 74: Installing Power Steering Pump Pulley Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. d. Connect the PS oil pressure switch connector. Install Generator and Drive Belt . Install RH Engine Under Cover. Install RH Front Wheel. Install Washer Tank. Fill With Engine Coolant. Start Engine And Check For Coolant Leaks.

18. 19. 20. 21. 22. 23.

CYLINDER HEAD
COMPONENTS

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Fig. 75: Cylinder Head Components (1 Of 3) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Fig. 76: Cylinder Head Components (2 Of 3) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Fig. 77: Cylinder Head Components (3 Of 3) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL 1. Drain Engine Coolant. 2. Remove Drive Belt And Alternator .

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

3. 4. 5. 6.

Remove Air Cleaner Hose. A/T: Disconnect Throttle Cable. Disconnect Accelerator Cable. Disconnect From Exhaust Pipe From Exhaust Manifold. a. Remove the 2 nuts, heated oxygen sensor and gasket. b. Remove the 2 bolts and 2 springs holding the front exhaust pipe to the exhaust manifold.

Fig. 78: Identifying Exhaust Pipe To Exhaust Manifold Mounting Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Remove the gasket. 7. Remove The 3 Bolts And Exhaust Manifold Stay.

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Fig. 79: Locating Exhaust Manifold Stay Mounting Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 8. Remove Exhaust Manifold. a. Remove the bolt, 2 nuts and heat insulator from the dash panel. b. Remove the 6 bolts and upper heat insulator. c. Remove the 5 nuts, exhaust manifold and gasket.

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Fig. 80: Locating Exhaust Manifold Mounting Nuts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. d. Remove the 3 bolts and lower heat insulator from the exhaust manifold. Remove Ignition Coils . Remove Spark Plugs . Remove PCV hoses . Remove Throttle Body . Remove Injectors . Disconnect Engine Wire From Cylinder Head. a. Disconnect the ECT sensor connector. b. Disconnect the camshaft position sensor connector.

9. 10. 11. 12. 13. 14.

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Fig. 81: Locating Camshaft Position Sensor Connector, Ground Wire & Engine Wire Protector Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Disconnect the 2 ground wires. d. Remove the 2 bolts, and disconnect the engine wire protector from the 2 brackets on the intake manifold. 15. Remove Intake Manifold. a. Disconnect the EVAP hose for ORVR.

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Fig. 82: Locating Components For Intake Manifold Removal & Installation Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disconnect the brake booster vacuum hose. c. Remove the bolt, nut and hose clamp. d. Remove the 2 bolts and manifold stay. e. Remove the 2 bolts, 2 nuts, 2 brackets, intake manifold and gasket. Remove Engine Hanger. Remove Camshaft Position Sensor . Remove ECT Sensor . Remove Oil Filler Cap. . Remove Camshaft Timing Sprockets. . See REMOVAL under TIMING CHAIN. Remove Camshafts. Uniformly loosen and remove the 19 bearing cap bolts, in several passes, in the sequence shown, and remove the 9 bearing caps, intake and exhaust camshafts.

16. 17. 18. 19. 20. 21.

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Fig. 83: Identifying Camshaft Bearing Cap Bolt Removal Sequence Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 22. Remove Camshaft Timing Oil Control Valve . 23. Remove Camshaft Timing Oil Control Valve Filter . 24. Remove Cylinder Head. a. Disconnect the upper radiator hose from the water hose union. b. Disconnect the heater water hose from the water hose union. CAUTION: Head warpage or cracking could result from removing bolts in an incorrect order.

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Fig. 84: Identifying Cylinder Head Bolt Removal Sequence Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Using a 10 mm bi-hexagon wrench, uniformly loosen and remove the 10 cylinder head bolts, in several passes, in the sequence shown. Remove the 10 cylinder head bolts and plate washers. d. Remove the bolt holding the water bypass pipe to the cylinder head. NOTE: Be careful not to damage the contact surfaces of the cylinder head and cylinder block.

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Fig. 85: Prying Cylinder Head Off Block Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. e. Using a screwdriver, pry between the cylinder head and cylinder block, and remove the cylinder head. DISASSEMBLY NOTE: Arrange the valve lifters in the correct order.

1. Remove Valve Lifters. 2. Remove Valves. a. Using SST, compress the valve spring and remove the 2 keepers. SST 09202-70020 (09202-00010).

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Fig. 86: Compressing Valve Spring Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. c. d. e. Remove the spring retainer. Remove the valve spring. Remove the valve. Remove the using needle-nose pliers, remove the oil seal.

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Fig. 87: Removing Oil Seal Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE: Arrange the valves, valve springs, spring seats and spring retainers in the correct order.

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Fig. 88: Removing Spring Seat Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. f. Using compressed air and a magnetic finger, remove the spring seat by blowing air. INSPECTION 1. Clean Top Surfaces Of Pistons And Cylinder Block. a. Turn the crankshaft, and bring each piston to top dead center (TDC). Using a gasket scraper, remove all the carbon from the piston surface.

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Fig. 89: Scraping Carbon From Piston Surface Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Using a gasket scraper, remove all the gasket material from the cylinder block surface.

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Fig. 90: Scraping Gasket Material From Cylinder Block Surface Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. WARNING: Protect your eyes when using high pressure compressed air. c. Using compressed air, blow carbon and oil from the bolt holes. 2. Inspect Cylinder Block For Flatness. 3. Clean Cylinder Head. CAUTION: Be careful not to scratch the cylinder block contact surface.

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Fig. 91: Scraping Gasket Material From Cylinder Head Surface Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. a. Using a gasket scraper, remove all the gasket material from the cylinder head contact surface. CAUTION: Be careful not to scratch the cylinder block contact surface.

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Fig. 92: Brushing Carbon From Combustion Chambers Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Using a wire brush, remove all the carbon from the combustion chambers. c. Using a soft brush and solvent, thoroughly clean the cylinder head.

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Fig. 93: Cleaning Cylinder Head Using Solvent & Soft Brush Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. d. Using a valve guide bushing brush and solvent, clean all the guide bushings.

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Fig. 94: Cleaning Guide Bushings Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 4. Inspect Cylinder Head. a. Inspect for flatness. Using a precision straight edge and a feeler gauge, measure the surface contacting the cylinder

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

block and the manifolds for warpage.Maximum warpage: 0.05 mm (0.0020 in.) . If warpage is greater than maximum, replace the cylinder head.

Fig. 95: Inspecting Cylinder Block, Intake & Exhaust Manifold Warpage Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Using a dye penetrate, Inspect the combustion chamber, intake ports, exhaust ports and cylinder

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

block surface for cracks.

Fig. 96: Spraying Dye Penetrate Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. If cracked, replace the cylinder head. 5. Clean Valves. a. Using a gasket scraper, chip off any carbon from the valve head.

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Fig. 97: Scraping & Brushing Valve Heads Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Using a wire brush, thoroughly clean the valve. 6. Inspect Valve Stems And Guide Bushings. a. Using a caliper gauge, measure the inside diameter of the guide bushing.Bushing inside diameter: 5.510 - 5.530 mm (0.2169 - 0.2177 in.) .

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Fig. 98: Measuring Guide Bushing Inside Diameter Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Using a micrometer, measure the diameter of valve stem.

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Fig. 99: Measuring Valve Stem Diameter Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 100: Valve Stem Diameter Specifications Chart Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Subtract the valve stem diameter measurement from the guide bushing inside diameter measurement.

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Fig. 101: Standard oil clearance Specifications Chart Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 102: Maximum oil clearance Specifications Chart Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. If the clearance is greater than maximum, replace the valve and guide bushing. See REPLACE VALVE GUIDE BUSHINGS. 7. Inspect Valves. a. Check the valve is ground to the correct valve face angle. Valve face angle: 44.5 .

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Fig. 103: Identifying Valve Angle Measurement Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Check that the surface of the valve for wear. If the valve face is worn, replace the valve. c. Check the valve head margin thickness.

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Fig. 104: Valve Margin Specification Chart Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 105: Identifying Valve Margin Measurement Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

If the margin thickness is less than minimum, replace the valve. d. Check the valve overall length.

Fig. 106: Measuring Overall Valve Length Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Fig. 107: Valve Standard Overall Length Specification Chart Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 108: Valve Minimum Overall Length Specification Chart Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. If the overall length is less than minimum, replace the valve. e. Check the surface of the valve stem tip for wear. If the valve stem tip is worn, replace the valve. 8. Inspect And Clean Valve Seats. a. Using a 45 carbide cutter, resurface the valve seats. Remove only enough metal to clean the seats.

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Fig. 109: Resurfacing Valve Seats Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. After resurfacing the valve seat 45, measure the residuary width of the valve seat 45.

Fig. 110: Minimum Valve Seat Residuary Width Chart Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. If the valve seat 45 residuary width is less than minimum, replace the cylinder head. c. Check the valve seating position. Apply a light coat of prussian blue (or white lead) to the valve face. Lightly press the valve against the seat. Do not rotate valve.

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Fig. 111: Inspecting Valve Seating Position Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. d. Check the valve face and seat for the following: If blue appears 360 around the face, the valve is concentric. If not, replace the valve. If blue appears 360 around the valve seat, the guide and face are concentric. If not, resurface the seat. Check that the seat contact is in the middle of the valve face with the following width: 1.0 - 1.4 mm (0.039 - 0.055 in.) If not, correct the valve seats as follows: 1. If the seating is too high on the valve face, use 30 and 45 cutters to correct the seat.

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Fig. 112: Correcting Valve Seated Too High Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 2. If the seating is too low on the valve face, use 60 and 45 cutters to correct the seat.

Fig. 113: Correcting Valve Seated Too Low Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

e. Hand-lap the valve and valve seat with an abrasive compound.

Fig. 114: Hand Lapping Valves Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. f. After hand-lapping, clean the valve and valve seat. 9. Inspect Valve Springs. a. Using a steel square, measure the deviation of the valve spring. Maximum deviation: 1.6 mm (0.063 in.) . Maximum angle (reference): 2 .

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Fig. 115: Measuring Valve Spring Deviation Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. If the deviation is greater than maximum, replace the valve spring. b. Using vernier calipers, measure the free length of the valve spring. Free length: 43.40 mm (1.7087 in.) .

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Fig. 116: Measuring Valve Spring Free Length Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. If the free length is not as specified, replace the valve spring. c. Using a spring tester, measure the tension of the valve spring at the specified installed length. Installed tension: 158.6 - 175.4 N (16.2 - 17.9 kgf, 35.7 - 39.5 lbf) at 33.6 mm (1.323 in.) . Maximum working tension: 335.3 - 370.7 N (34.2 - 37.8 kgf, 75.4 - 83.3 lbf) at 24.1 mm (0.949 in.) .

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Fig. 117: Measuring Valve Spring Tension

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. If the installed tension is not as specified, replace the valve spring. 10. Inspect Camshaft. a. Inspect for runout. 1. Place the camshaft on V-blocks. 2. Using a dial indicator, measure the circle runout at the center journal. Maximum circle runout: 0.03 mm (0.0012 in.) .

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Fig. 118: Measuring Camshaft Runout At Center Journal Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. If the circle runout is greater than maximum, replace the camshaft. b. Inspect the cam lobes.

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Using a micrometer, measure the cam lobe height.

Fig. 119: Measuring Cam Lobe Height Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 120: Standard Cam Lobe Height Specifications Chart Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Fig. 121: Minimum Cam Lobe Height Specifications Chart Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. If the lobe height is less than minimum, replace the camshaft. c. Inspect the camshaft journals. Using a micrometer, measure the journal diameter.

Fig. 122: Journal Diameter Specifications Chart Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. If the journal diameter is not as specified, check the oil clearance.

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Fig. 123: Measuring Journal Diameter Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. d. Inspect the journal clearance. 1. Clean the bearing caps and camshaft journals. 2. Place the camshafts on the cylinder head. 3. Lay a strip of Plastigage across each of the camshaft journal.

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Fig. 124: Placing Plastigage On Camshaft Journal Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE: Do not turn the camshaft.

4. Install the bearing caps. See step 3 a. Torque: 23 N.m (235 kgf.cm, 17 ft.lbf) for No. 1 . Torque: 13 N.m (133 kgf.cm, 10 ft.lbf) for No. 3 . 5. Remove the bearing caps.

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Fig. 125: Removing Bearing Caps Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 6. Measure the Plastigage at its widest point.

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Fig. 126: Measuring Plastigage Wide Point Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Standard oil clearance: 0.035 - 0.072 mm (0.0014 - 0.0028 in.) . Maximum oil clearance: 0.10 mm (0.0039 in.) . If the oil clearance is greater than maximum, replace the camshaft. If necessary, replace the bearing caps and cylinder head as a set. 7. Remove the Plastigage completely. 8. Remove the camshafts. e. Inspect the thrust clearance. 1. Install the camshafts. See INSTALLATION. 2. Using a dial indicator, measure the thrust clearance while moving the camshaft back and forth.

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Fig. 127: Measuring Camshaft Thrust Clearance Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Standard thrust clearance: 0.040 - 0.095 mm (0.0016 - 0.0037 in.) . Maximum thrust clearance: 0.11 mm (0.0043 in.) . If the thrust clearance is greater than maximum, replace the camshaft. If necessary, replace the bearing caps and cylinder head as a set. 3. Remove the camshaft. 11. Inspect VVT timing sprocket (valve timing controller assembly) . NOTE: Do not apply tape in the range from the tip of the camshaft to 18 mm (0.71 in.) from that tip.

a. Apply vinyl tape to all the ports except the one indicated by the arrow in the illustration. NOTE: Do not push VVT timing sprocket to the camshaft forcibly when installing it.

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Fig. 128: Inspecting VVT timing sprocket (1 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Install the VVT timing sprocket. Torque: 54 N.m (550 kgf.cm, 40 ft.lbf) . c. Check that the VVT timing sprocket will not turn. NOTE: When the oil splashes, wipe it off with a shop rag and the likes. Depending on the air pressure, the VVT timing sprocket will turn to the advance angle side without applying force by hand. Also, under the condition that the pressure can be hardly applied because of the air leakage from the port, there may be the case that the lock pin could be hardly released.

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Fig. 129: Inspecting VVT timing sprocket (2 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. d. Wind tape around the tip of the air gun and apply air of approximately 100 kPa (1 kgf/cm2 , 14 psi) to the port of the camshaft. Perform this in order to release the lock pin for the maximum delay angle locking. e. Under the condition of (c), turn the VVT timing sprocket to the advance angel side (the arrow marked direction in the illustration) with your hand.Standard: Must turn f. Except the position where the lock pin meets at the maximum delay angle, let the VVT timing sprocket turn back and forth and check the movable range and that there is no disturbance. Standard: Movable smoothly in the range about 30 . g. Turn the VVT timing sprocket with your hand and lock it at the maximum delay angel position. 12. Inspect Valve Lifters And Lifter Bores. a. Using a caliper gauge, measure the lifter bore diameter of the cylinder head. Lifter bore diameter: 31.000 - 31.025 mm (1.2205 - 1.2215 in.) .

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Fig. 130: Measuring Cylinder Head Lifter Bore Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Using a micrometer, measure the lifter diameter. Lifter diameter: 30.966 - 30.976 mm (1.2191 - 1.2195 in.) .

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Fig. 131: Measuring Lifter Diameter Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Subtract the lifter diameter measurement from the lifter bore diameter measurement. Standard oil clearance: 0.024 - 0.059 mm (0.0009 - 0.0023 in.) . Maximum oil clearance: 0.079 mm (0.0031 in.) . If the oil clearance is greater than maximum, replace the lifter. If necessary, replace the cylinder head. 13. Inspect Intake Manifold. Using a precision straight edge and feeler gauge, measure the surface contacting the cylinder head for warpage. Maximum warpage: 0.10 mm (0.0039 in.) .

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Fig. 132: Inspecting Intake Manifold Warpage Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. If warpage is greater than maximum, replace the manifold. 14. Inspect Exhaust Manifold. Using a precision straight edge and feeler gauge, measure the surface contacting the cylinder head for warpage. Maximum warpage: 0.70 mm (0.0276 in.) .

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Fig. 133: Inspecting Exhaust Manifold Warpage Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. If warpage is greater than maximum, replace the manifold. 15. Inspect Cylinder Head Bolts. Standard overall length: 156.0 - 159.0 mm (6.142 - 6.260 in.) . Maximum overall length: 159.5 mm (6.280 in.) .

Fig. 134: Inspecting Overall Bolt Length Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. If the overall length is greater than maximum, replace the bolt. REPLACE VALVE GUIDE BUSHINGS a. Gradually heat the cylinder head to 80 - 100C (176 - 212F).

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Fig. 135: Heating Cylinder Heads Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Using SST and a hammer, tap out the guide bushing. SST 09201-01055, 09950-70010 (09951-07100).

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Fig. 136: Removing Guide Bushings Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Using a caliper gauge, measure the bushing bore diameter of the cylinder head.

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Fig. 137: Measuring Cylinder Head Bushing Bore Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. If the bushing bore diameter of the cylinder head is greater than 10.306 mm (0.4057 in.), machine the bushing bore to the following dimension: 10.335 - 10.356 mm (0.4068 - 0.4077 in.) . If the bushing bore diameter of the cylinder head is greater than 10.356 mm (0.4077 in.), replace the cylinder head. d. Select a new guide bushing (STD or O/S 0.05).

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Fig. 138: Intake & Exhaust Cylinder Head Bushing Bore Specifications Chart Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. e. Gradually heat the cylinder head to 80 - 100C (176 - 212F). f. Using SST and a hammer, tap in a new guide bushing to the specified protrusion height. Protrusion height: 8.7 - 9.1 mm (0.342 - 0.358 in.) SST 09201-01055, 09950-70010 (09951-07100 ).

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Fig. 139: Installing Guide Bushing & Inspecting Specified Protrusion Height Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. g. Using a sharp 5.5 mm reamer, ream the guide bushing to obtain the standard specified clearance between the guide bushing and valve stem. See step 6 under INSPECTION.

Fig. 140: Reaming Guide Bushings Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REASSEMBLY NOTE:

Thoroughly clean all parts to be assembled. Before installing the parts, apply fresh engine oil to all sliding and rotating surfaces. Replace oil seals with new ones. When using a new cylinder head, water hose unions must be installed.

NOTE:

1. Install Water Hose Unions. a. Mark the standard position away from the edge, onto the water hose union.

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Fig. 141: Marking Standard Insertion Length On Water Hose Union Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Apply adhesive to the water hose union hole of the cylinder head. Adhesive: Part No. 0883300070, Three Bond 1324 or equivalent .

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Fig. 142: Identifying Adhesive Application Points Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE: Avoid pressing a new water hose union in too far by measuring the amount of protrusion while pressing.

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Fig. 143: Identifying Standard Protrusion Measurement Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Using a press, press in a new water hose union until there is protruding from the cylinder head. Standard protrusion: A: 29 mm (1.14 in.). B: 66.5 mm (2.618 in.). C: 24 mm (0.95 in.). 2. Install Valves. CAUTION: Pay much attention assembling the oil seal for intake and

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

exhaust. Assembling the wrong one may cause a failure.

Fig. 144: Installing Intake & Exhaust Valve Oil Seals Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Fig. 145: Identifying Intake & Exhaust Valve Oil Seal Differences Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. a. Using SST, push in a new oil seal. The intake valve oil seal is light brown and the exhaust valve oil seal is gray. SST 09201-41020. b. Install the valve (1), spring (2), valve spring (3) and spring retainer (4).

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Fig. 146: Identifying Valve Components Installation Order Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Using SST, compress the valve spring and place the 2 keepers around the valve stem. SST 09202-70020 (092002-00010).

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Fig. 147: Compressing Valve Springs Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. CAUTION: Be careful not to damage the valve stem tip.

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Fig. 148: Checking Valve For Proper Fit Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. d. Using a plastic-faced hammer and the valve stem (not in use) tip wound with vinyl tape, lightly tap the valve stem tip to ensure a proper fit. 3. Install Valve Lifters. a. Install the valve lifter. b. Check that the valve lifter rotates smoothly by hand. INSTALLATION NOTE:

Thoroughly clean all parts to be assembled. Before installing the parts, apply fresh engine oil to all sliding and rotating surfaces. Replace all gaskets and oil seals with new ones.

1. Place Cylinder Head On Cylinder Block. NOTE: Be careful of the installation direction.

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Fig. 149: Locating Cylinder Head Gasket Lot Number Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. a. Place a new cylinder head gasket on the cylinder block surface with the Lot No. stamp upward. b. Place the cylinder head quietly in order not to damage the gasket with the bottom part of the head. NOTE:

The cylinder head bolts are tightened in 2 progressive steps (steps (a) and (c)). If any cylinder head bolt is broken or deformed, replace it.

2. Install Cylinder Head Bolts. a. Apply a light coat if engine oil on the threads and under the heads of the cylinder head bolts. b. Using a 10 mm bi-hexagon wrench, install and uniformly tighten the 10 cylinder head bolts and plate washers, in several passes, in the sequence shown. Torque: 49 N.m (500 kgf.cm, 36 ft.lbf) . If any one of the cylinder head bolts does not meet the torque specification, replace the cylinder head bolt.

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Fig. 150: Identifying Cylinder Head Bolt Installation Sequence Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Mark the front of the cylinder head bolt with paint. d. Retighten the cylinder head bolts 90 in the numerical order shown. e. Check that the paint mark is not at a 90 angle to the front.

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Fig. 151: Identifying Bolt Tightening Increments Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. f. Install the bolt holding the water bypass pipe to the cylinder head. g. Connect the upper radiator hose to the water hose unions. h. Connect the heater hose to the water hose unions.

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Fig. 152: Installing Heater Hose Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 3. Install Camshafts. a. Place the 2 camshafts on the cylinder head with the No. 1 cam lobes facing as shown the illustration.

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Fig. 153: Identifying No. 1 Cam Lobe Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE: No.3 camshaft bearing cap has a number and front mark.

b. Install the bearing caps in their proper locations. c. Apply a light coat of engine oil on the threads and under the heads of the bearing cap bolts.

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Fig. 154: Identifying Bearing Cap Installation Locations Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. d. Install and uniformly tighten the 19 bearing cap bolts. After tightening the No.1 camshaft bearing cap, tighten then in several passes, in the sequence shown.

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Fig. 155: Identifying Camshaft Bearing Cap Bolt Installation Sequence Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Torque: 23 N.m (235 kgf.cm, 17 ft.lbf) for No. 1 . 13 N.m (133 kgf.cm, 10 ft.lbf) for No. 3 . Check And Adjust Valve Clearance. See ADJUSTMENT under VALVE CLEARANCE. Install Camshaft Timing Oil Control Valve . Install Camshaft Timing Oil Control Valve Filter . Install camshaft timing sprockets. See 1 in INSTALLATION under TIMING CHAIN. Install oil filler cap . Install ECT Sensor . Install Camshaft Position Sensor . Install Engine Hanger. Install the craw of the stopper pressing it on the stopper lip of the cylinder head. Torque: 38 N.m (388 kgf.cm, 28 ft.lbf) . 12. Install Intake Manifold. a. Install a new gasket, the intake manifold and 2 brackets with the 2 bolts and 2 nuts. Uniformly

4. 5. 6. 7. 8. 9. 10. 11.

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

tighten the bolts and nuts in several passes.Torque: 18.5 N.m (189 kgf.cm, 14 ft.lbf) .

Fig. 156: Locating Components For Intake Manifold Removal & Installation Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Install the manifold stay with the 2 bolts. Torque: 18.5 N.m (189 kgf.cm, 14 ft.lbf) . c. Install the hose clamp with the bolt and nut. Torque: 18.5 N.m (189 kgf.cm, 14 ft.lbf) . d. Connect the EVAP hose for ORVR. e. Connect the brake booster vacuum hose. 13. Connect Engine Wire To Cylinder Head. a. Install the engine wire protector to the 2 brackets on the intake manifold with the 2 bolts.

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Fig. 157: Locating Camshaft Position Sensor Connector, Ground Wire & Engine Wire Protector Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Connect the ECT sensor connector. c. Connect the camshaft position sensor connector. d. Connect the 2 ground wires. Install Injectors . Install Throttle Body ) . Install PCV hoses . Install Spark Plugs . Install Ignition Coils . Install Exhaust Manifold. a. Install the lower heat insulator to the exhaust manifold with the 3 bolts. Torque: 12 N.m (123 kgf.cm, 9 ft.lbf) . b. Install a new gasket and the exhaust manifold with the 5 nuts. Uniformly tighten the nuts in several passes. Torque: 37 N.m (377 kgf.cm, 27 ft.lbf) .

14. 15. 16. 17. 18. 19.

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Fig. 158: Locating Exhaust Manifold Mounting Nuts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Install the upper heat insulator with the 6 bolts. Torque: 12 N.m (123 kgf.cm, 9 ft.lbf) . d. Install the heat insulator to the dash panel with the bolt and 2 nuts. 20. Install the manifold stay with the 3 bolts. Alternately tighten the bolts. Torque: 49 N.m (500 kgf.cm, 37 ft.lbf) .

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Fig. 159: Locating Exhaust Manifold Stay Mounting Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 21. Connect front exhaust pipe to exhaust manifold : a. Place a new gasket to the exhaust manifold.

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Fig. 160: Installing Exhaust Pipe To Exhaust Manifold Mounting Gasket & Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Install the 2 bolts and 2 springs holding the front exhaust pipe to the exhaust manifold. c. Install a new gasket and the heated oxygen sensor with the 2 new nuts. Torque: 20 N.m (200 kgf.cm, 14 ft.lbf) . Connect accelerator cable . A/T: connect throttle cable . Install air cleaner hose . Install Generator and Drive Belt . Fill with engine coolant . Start engine and check for leaks . Recheck engine coolant level and oil level .

22. 23. 24. 25. 26. 27. 28.

ENGINE UNIT
COMPONENTS

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Fig. 161: Locating Engine Unit Components (1 Of 4) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Fig. 162: Locating Engine Unit Components (2 Of 4) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Fig. 163: Locating Engine Unit Components (3 Of 4) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Fig. 164: Locating Engine Unit Components (4 Of 4) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL 1. Remove Battery And Tray.

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

2. 3. 4. 5. 6. 7. 8. 9.

Remove Hood. Remove Engine Under Covers. Drain Engine Coolant. Drain Engine Oil. Drain Transaxle Oil. Disconnect Accelerator Cable. Remove Washer Tank. With Cruise Control System: Disconnect cruise control actuator from body. a. Disconnect the actuator connector. b. Disconnect the wire clamp from the actuator bracket. c. Remove the 3 bolts, and disconnect the actuator from the body.

Fig. 165: Locating Cruise Control Actuator Mounting Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 10. Remove Air Cleaner Cap. a. Disconnect the MAF meter connector.

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Fig. 166: Locating MAF Meter Connectors Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disconnect the VSV connector for canister closed valve. c. Disconnect the air hose from air cleaner cap. d. Disconnect the 2 clamps, and disconnect the air cleaner cap from the air cleaner case. e. Loosen the hose clamp, and disconnect the air cleaner hose from the throttle body. f. Remove the air cleaner cap and air cleaner hose assembly. 11. Remove Air Cleaner Case. a. Remove the air filter. b. Disconnect the engine wire from the clamp on the air cleaner case. c. Remove the bolt holding VSV bracket to the air cleaner case. d. Remove the 3 bolts and air cleaner case.

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Fig. 167: Locating Air Cleaner Case Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE: Letters for steps a through d are called out in figure. See Fig. 168.

12. Disconnect Tube, Hoses And Connectors. a. Remove the fuel tube clamp.

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Fig. 168: Locating Step 12 Components Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disconnect the fuse tube from fuel pipe on vehicle side. c. Disconnect the heater hose from water bypass pipe. d. Disconnect the brake booster vacuum hose from pipe. e. Disconnect the heater hose from water hose union on cylinder head. f. Disconnect the DLC1. 13. Remove Generator And Drive Belt . 14. Remove Radiator Assembly . 15. With A/C: disconnect A/C compressor from engine: a. Disconnect the A/C compressor connector. NOTE: Suspend the A/C compressor securely.

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Fig. 169: Locating A/C Compressor Mounting Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Using a torx socket (T40), remove the 3 bolts, and disconnect the A/C compressor from the engine. 16. M/T: Disconnect Clutch Release Cylinder From Transaxle. a. Remove the bolt, and disconnect the bracket from the transaxle.

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Fig. 170: Locating clutch release cylinder bracket, clamp & mounting bolt Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the clamp bolt, and disconnect the tube from the transaxle. c. Remove the 2 bolts, and disconnect the release cylinder from the transaxle. 17. Disconnect Transaxle Control Cable(s) From Transaxle. .

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Fig. 171: Locating Control Cable Bracket Mounting Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

18. Disconnect Engine Wire From Engine Compartment Relay Box. a. Remove the 2 bolts and disconnect the relay box. b. Disconnect the 3 connectors. c. Disconnect the negative cable from the 2 clamps on the engine wire. d. Disconnect the positive cable from the engine wire.

Fig. 172: Locating Engine Compartment Relay Box Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. e. Remove the bolt, and disconnect the ground cable from the transaxle.

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Fig. 173: Locating Ground Cable Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 19. Disconnect Engine Wire From Cabin. a. Remove the Finish Lower Center Panel . b. Remove the 3 bolts and disconnect the ECM. c. Disconnect the 3 (M/T and 3 A/T) or 4 (4 A/T) ECM connectors.

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Fig. 174: Locating Engine Wire Connectors From Cabin Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. d. Disconnect the 5 cowl wire connectors from connectors on bracket. e. Disconnect the heated oxygen sensor (Bank 1 sensor 2) connector. f. Pull out the engine wire from the cabin.

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Fig. 175: Locating Engine Wire From Cabin Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 20. Disconnect PS Pump From Engine. a. Disconnect the PS oil pressure switch connector. b. Using SST, remove the pulley bolt. SST 09960-10010 (09962-01000, 09963-01000). c. Remove the PS pump pulley.

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Fig. 176: Removing Power Steering Pump Pulley Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE: Put aside the pump and suspend it to the cowl with a string.

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Fig. 177: Locating Power Steering Pump Through Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. d. Remove the 2 nuts and through bolts, and disconnect the PS pump from the engine. 21. Remove Front Exhaust Pipe. a. Remove the bolt and pipe clamp, and disconnect the center exhaust pipe from the front exhaust pipe.

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Fig. 178: Locating Center Exhaust Pipe Mounting Bolt Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the 2 bolts holding the front pipe to the exhaust manifold. c. Remove the front exhaust pipe and 2 gaskets. 22. Remove Drive Shafts .

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Fig. 179: Locating Front Pipe To Exhaust Manifold Mounting Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 23. Remove The 2 Bolts, Nut And Drive Shaft Heat Insulator.

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Fig. 180: Locating Drive Shaft Heat Insulator Mounting Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 24. Remove Front Engine Mounting Bracket. a. Remove the through bolt and nut holding the front mounting insulator to the mounting bracket. b. Remove the 2 bolt and front engine mounting bracket.

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Fig. 181: Locating Front Engine Mounting Bracket Mounting Bolt Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 25. Remove Rear Mounting Bracket. a. Remove the through bolt holding the rear mounting insulator to the mounting bracket.

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Fig. 182: Locating Rear Mounting Bracket Through & Mounting Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the 3 (M/T and 4 A/T) or 2 (3 A/T) bolts and rear engine mounting bracket. 26. Attach Engine Sling Device To Engine Hangers. Remove the 2 nuts, 2 clips and No. 2 cylinder head cover. 27. Remove Engine And Transaxle Assembly From Vehicle. a. Install the 2 engine hangers in the correct direction.

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Fig. 183: Installing Engine Hangers Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Engine hanger part No.: Front: 12281-20021. Rear: 12281-15040. Bolt part No.: 91512-B1016 2 pieces. Torque: 38 N.m (388 kgf.cm, 28 ft.lbf) . WARNING: Do not attempt to hang the engine by hooking the chain to any other part. b. Attach the engine sling device to the engine hangers. c. M/T: Remove the 2 bolts and LH mounting stay.

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Fig. 184: Locating Left Side Engine Mount Through & Mounting Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. d. e. f. g. Remove the through bolt and nut holding the LH mounting insulator to the mounting bracket. Remove the 4 bolts and LH engine mounting insulator. Disconnect the ground strap from the body. Remove the bolt and 2 nuts, and disconnect the RH engine mounting bracket from the RH engine mounting insulator.

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Fig. 185: Locating Right Side Crounding Strap, Engine Mount Mounting Bolts & Nuts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. h. Remove the bolt holding the A/C piping clamp from the RH engine mounting insulator. i. Remove the 3 bolts and RH engine mounting insulator.

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Fig. 186: Locating Right Side A/C Clamp, Engine Mount Through & Mounting Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. CAUTION: Make sure the engine is clear of steering gear assembly all wiring, hoses and cables.

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Fig. 187: Removing Engine From Engine Compartment Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. j. Lift the engine out of the vehicle slowly and carefully. k. Place the engine and transaxle assembly onto the stand. 28. Separate Engine And Transaxle. For M/T: See Separate Engine And Transaxle .

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

For (AT (A131L): See Separate Engine And Transaxle . For (A/T (A245E): See Separate Engine And Transaxle . INSTALLATION 1. Assemble Engine And Transaxle For M/T: See Assemble Engine And Transaxle . For (AT (A131L): See Assemble Engine And Transaxle . For (A/T (A245E): See Assemble Engine And Transaxle . 2. Install Engine And Transaxle Assembly In Vehicle. a. Attach the engine sling device to the engine hangers. CAUTION: Be careful not to hit the steering gear assembly.

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Fig. 188: Installing Engine Into Engine Compartment Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Lower the engine into the engine compartment. Tilt the transaxle downward, lower the engine and clear the LH mounting. c. Keep the engine level, and align RH and LH mountings with the body bracket.

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

d. Install the RH engine mounting insulator with the 3 bolts. Torque: 63.7 N.m (650 kgf.cm, 47 ft.lbf) for bolt A . 25.5 N.m (260 kgf.cm, 19 ft.lbf) for bolt B . e. Install the bolt holding the A/C piping clamp to the RH engine mounting insulator.

Fig. 189: Locating Right Side A/C Clamp, Engine Mount Through & Mounting Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. f. Install the RH engine mounting bracket to the RH engine mounting insulator with the bolt and 2 nuts. Torque: 63.7 N.m (650 kgf.cm, 47 ft.lbf) for bolt . 52.0 N.m (530 kgf.cm, 38 ft.lbf) for nut . g. Connect the ground strap to the body.

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Fig. 190: Locating Right Side Crounding Strap, Engine Mount Mounting Bolts & Nuts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. h. Install the LH engine mounting insulator with the 4 bolts. Torque: 65.0 N.m (660 kgf.cm, 48 ft.lbf) . i. Install the through bolt and nut holding the LH mounting insulator to the mounting bracket. Torque: 87 N.m (890 kgf.cm, 64 ft.lbf) . j. M/T: Install the LH mounting stay with the 2 bolts. Torque: 20.6 N.m (210 kgf.cm, 15 ft.lbf) .

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Fig. 191: Locating Left Side Engine Mount Through & Mounting Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 3. Install Rear Engine Mounting Bracket. a. Install the rear engine mounting bracket with the 3 (M/T, 4 A/T) or 2 (3 A/T) bolts. Torque: 77.5 N.m (790 kgf.cm, 57 ft.lbf) . b. Install the through bolt holding the rear mounting insulator to the mounting bracket. Torque: 87.3 N.m (890 kgf.cm, 64 ft.lbf) .

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Fig. 192: Locating Rear Mounting Bracket Through & Mounting Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 4. Install Front Engine Mounting Bracket a. Install the front mounting bracket holding the 2 bolts. Torque: 77.5 N.m (790 kgf.cm, 57 ft.lbf) .

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Fig. 193: Locating Front Engine Mounting Bracket Mounting Bolt Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Install the through bolt and nut holding the front mounting insulator to the mounting bracket. Torque: 87.3 N.m (890 kgf.cm, 64 ft.lbf) . 5. Install The Drive Shaft Heat Insulator With The 2 Bolts And Nut. Torque: 16.5 N.m (170 kgf.cm, 13 ft.lbf) . 6. Install Drive Shafts . 7. Install Front Exhaust Pipe. a. Place a new gasket to the exhaust manifold. b. Install the 2 bolts and 2 springs holding the front exhaust pipe to the exhaust manifold. Torque: 62 N.m (630 kgf.cm, 46 ft.lbf) .

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Fig. 194: Installing Front Exhaust Pipe To Exhaust Manifold Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. d. e. f. Place a new gasket to the rear of the front exhaust pipe. Attach the front exhaust pipe to the center exhaust pipe. Install a new pipe clamp with the bolt. Torque: 32 N.m (330 kgf.cm, 24 ft.lbf) . Install a new gasket and the heated oxygen sensor with 2 new nuts. Torque: 20 N.m (200 kgf.cm, 14 ft.lbf) .

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Fig. 195: Installing Center Exhaust Pipe & Mounting Bolt Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 8. Install the PS pump. a. Install the PS pump with the 2 through bolts and nuts. Torque: 37 N.m (370 kgf.cm, 27 ft.lbf) . b. Install the PS pump pulley with the pulley nut. c. Using SST, torque the pulley nut.Torque: 43 N.m (440 kgf.cm, 32 ft.lbf) . SST 09960-10010 (09962-01000, 09963-01000)

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Fig. 196: Installing Power Steering Pump Pulley Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. d. Connect the PS oil pressure switch connector. Connect Engine Wire To Cable. a. Push in the engine wire to the cabin. b. Connect the 3 (M/T and 3 A/T) or 4 (4 A/T) ECM connectors. c. Connect the 5 cowl wire connectors to connectors on bracket. d. Connect the heated oxygen sensor (bank 1 sensor 2) connector. e. Install the ECM with the 3 bolts. f. Install The Finish Lower Center Panel . Connect Engine Wire To Engine Comportment Relay Box. a. Connect the ground cable to the transaxle. b. Connect the positive cable to the engine wire. c. Connect the negative cable to the 2 clamps on the engine wire. d. Connect the 3 connectors. e. Install the relay box with the 2 bolts. Connect Transaxle Control Cable(S) To Transaxle. MT: Connect Clutch Release Cylinder To Transaxle.

9.

10.

11. 12.

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Torque: 12 N.m (120 kgf.cm, 9 ft.lbf) 13. With A/C: Install A/C Compressor. a. Using a torx socket (T40), install the A/C compressor with the 3 bolts. Torque: 24.5 N.m (245 kgf.cm, 18 ft.lbf) b. Connect the A/C compressor connector.

Fig. 197: Locating A/C Compressor Mounting Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 14. Install Radiator Assembly. 15. Install Generator And Drive Belt . NOTE: Letters for steps a through d are called out in figure. See Fig. 168.

16. Connect Connectors, Hoses And Tube. a. Connect the DLC1.

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Fig. 198: Locating Step 16 Components Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Connect the Heater hose to water hose union on cylinder head. c. Connect the brake booster vacuum hose to pipe. d. Connect the heater hose to water bypass pipe. e. Connect the fuel tube to fuel pipe on vehicle side. f. Install the fuel tube clamp. 17. Install Air Cleaner Case. a. Install the air cleaner case with the 3 bolts. b. Install the bolt holding VSV bracket to the air cleaner case. c. Connect the engine wire to the clamp on the air cleaner case. d. Install the air filter.

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Fig. 199: Locating Air Cleaner Case Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 18. Install Air Cleaner Cap. a. Connect the air cleaner hose to the throttle body. b. Attach the air cleaner cap to the air cleaner case, and install the 2 clamps. c. Tighten the air cleaner hose clamp. d. Connect the air hose for cleaner cap. e. Connect the MAF meter connector.

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Fig. 200: Locating MAF Meter Connectors Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. f. Connect the VSV connector for canister closed valve. 19. With Cruise Control System, Install Cruise Control Actuator. a. Install the actuator with the 3 bolts.

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Fig. 201: Locating Cruise Control Actuator Mounting Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Connect the wire clamp to the actuator bracket. c. Connect the actuator connector. Install Washer Tank. Connect Accelerator Cable. Install Engine Under Covers. Install Hood. Fill Engine With Oil. Fill With Engine Coolant. Start Engine And Check For Leaks. Recheck Engine Coolant And Oil Levels.

20. 21. 22. 23. 24. 25. 26. 27.

CYLINDER BLOCK
COMPONENTS

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Fig. 202: Locating Cylinder Block Components (1 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Fig. 203: Locating Cylinder Block Components (2 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. DISASSEMBLY 1. M/T: Remove Flywheel.

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

2. 3. 4. 5. 6. 7.

A/T: Remove Drive Plate. Install Engine To Engine Stand For Disassembly. Remove Timing Chain And Sprockets. . See REMOVAL under TIMING CHAIN Remove Cylinder Head. See 24 in REMOVAL under CYLINDER HEAD. Remove Engine Wire. Remove Oil Dipstick And Guide. a. Remove the 2 bolts and oil dipstick and guide. b. Remove the O-ring from the dipstick.

Fig. 204: Locating Oil Dipstick Guide Mounting Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 8. 9. 10. 11. 12. 13. 14. Remove The 2 Nuts, Bolt And Water Bypass Pipe. Remove Thermostat. Remove Knock Sensor. Remove Engine Coolant Drain Union. Remove Oil Pump Remove Oil Filter Using A 12-mm Hexagon Wrench, Remove The Oil Filter Union.

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Fig. 205: Locating Oil Filter Union Bolt Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 15. Remove Oil Pan. a. Remove the 14 bolts and 2 nuts.

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Fig. 206: Locating Oil Pan Bolts & Nuts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. CAUTION:

Be careful not to the damage the oil pan contact surface of the bearing cap subassembly. Be careful not to damage the oil pan flange.

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Fig. 207: Using Oil Pan Removal SST Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Insert the blade of SST between the bearing cap subassembly and oil pan, and cut off applied sealer and remove the oil pan. SST 09032-00100 . 16. Remove The 2 Nuts, Bolt, Oil Strainer And Gasket.

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Fig. 208: Locating Oil Strainer Mounting Bolts & Nuts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 17. Using A Dial Indicator, Measure The Thrust Clearance While Moving The Connecting Rod Back And Forth. Standard thrust clearance: 0.160 - 0.342 mm (0.0063 - 0.0135 in.) . Maximum thrust clearance: 0.342 mm (0.0135 in.) . If the thrust clearance is greater than maximum, replace the connecting rod assembly(s). If necessary, replace the crankshaft. Connecting rod thickness: 19.788 - 19.840 mm (0.0779 - 0.0781 in.) .

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Fig. 209: Measure Connecting Rod Thrust Clearance Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 18. Remove Connecting Rod Caps And Check Oil Clearance. a. Check the matchmarks on the connecting rod and cap are aligned to ensure correct reassembly. b. Remove the 2 connecting rod cap bolts.

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Fig. 210: Locating Connecting Rod Cap Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE: Keep the lower bearing inserted with the connecting rod cap.

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Fig. 211: Removing Connecting Rod Cap Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Using the 2 removed connecting rod cap bolts, remove the connecting rod cap and lower bearing by wiggling the connecting rod cap right and left. d. Clean the crank pin and bearing. e. Check the crank pin and bearing for pitting and scratches.

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Fig. 212: Inspecting Crank Pin & Bearing Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. If the crank pin or bearing is damaged, replace the bearings. If necessary, replace the crankshaft. f. Lay a strip of Plastigage the crank pin.

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Fig. 213: Applying Plastigage To Crank Pin Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. g. Install the connecting rod cap with the 2 bolts. See step 12-14 under REASSEMBLY. NOTE: Do not turn the crankshaft.

h. Remove the 2 bolts, connecting rod cap and lower bearing (See steps (a) and (b )).

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Fig. 214: Installing Connecting Rod Cap Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. i. Measure the Plastigage at its widest point.

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Fig. 215: Measuring Plastiguage Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Standard oil clearance: 0.028 - 0.060 mm (0.0011 - 0.0024 in.) . Maximum oil clearance: 0.08 mm (0.0031 in.) . NOTE: If replacing a bearing, replace it with one having the same number as marked on the connecting rod. There are 3 sizes of standard bearings, marked "1", "2" and "3" accordingly.

If the oil clearance is greater than maximum, replace the bearings. If necessary, grind or replace the crankshaft.

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Fig. 216: Standard bearing center wall thickness Chart Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Fig. 217: Locating Bearing & Connecting Rod Marks Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. j. Completely remove the Plastigage. 19. Remove Piston And Connecting Rod Assembles. a. Using a ridge reamer, remove all the carbon from the top of the cylinder. NOTE:

Keep the bearings, connecting rod and cap together. Arrange the piston and connecting rod assemblies in the correct order.

Fig. 218: Ridge Reaming Cylinders Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Push the piston, connecting rod assembly and upper bearing through the top of the cylinder block. 20. Remove Bearing Cap Subassembly And Crankshaft Rear Oil Seal, And Check Oil Clearance. a. Remove the 10 hexagon head bearing cap subassembly bolts. b. Uniformly loosen and remove the 10 bearing cap subassembly bolts, in several passes, in the sequence shown.

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Fig. 219: Identifying Bolt Removal Sequence Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. CAUTION: Be careful not to damage the contact surfaces of the cylinder block and bearing cap subassembly. Keep the lower bearing and bearing cap subassembly together.

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Fig. 220: Locating Prying Points Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Using a screwdriver, remove the bearing cap subassembly by prying the portions between the cylinder block and bearing cap subassembly. Remove the 5 lower main bearings. d. Remove the crankshaft rear oil seal. NOTE: Keep the upper bearings together with the cylinder block.

e. Lift out the crankshaft. f. Clean each main journal and bearing. g. Check each main journal and bearing for pitting and scratches. If the journal or bearing is damaged, replace the bearings. If necessary, replace the crankshaft.

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Fig. 221: Inspecting main Journals & Bearings Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. h. Place the crankshaft on the cylinder block. i. Lay a strip of Plastigage across each journal.

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Fig. 222: Applying Plastiguage To Journals Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE: Do not turn the crankshaft.

j. Install the bearing cap subassembly. See 8 in REASSEMBLY. k. Remove the bearing cap subassembly (See steps () to (d)).

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Fig. 223: Identifying Bearing Cap Tightening Sequence Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. l. Measure the Plastigage at its widest point.

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Fig. 224: measuring main Journal Plastiguage Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. If the oil clearance is greater then maximum, replace the bearings. If necessary, replace the crankshaft. Standard oil clearance: 0.015 - 0.032 mm (0.0006 - 0.0013 in.) . Maximum oil clearance: 0.050 mm (0.0020 in.) . NOTE: If using a standard bearing, replace it with one having the same num If the number of the bearing cannot be determined, select the correc bearing by adding together the numbers imprinted on the cylinder b and crankshaft, then selecting the bearing with the same number as total. There are 4 sizes of standard bearings, marked "1", "2", "3" an accordingly.

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Fig. 225: Bearing Number Sizing Chart Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Fig. 226: Locating Jornal Bearing Sizeing Marks Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. EXAMPLE: Cylinder block "4" (A) + Crankshaft "3" (B) = Total number 7 (Use bearing "3")

Fig. 227: Reference Chart Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. m. Completely remove the Plastigage. 21. Check Crankshaft Thrust Clearance. Using a dial indicator, measure the thrust clearance while prying the crankshaft back and forth with a screwdriver.

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Fig. 228: Measuring Check Crankshaft Thrust Clearance Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Standard thrust clearance: 0.04 - 0.24 mm (0.0016 - 0.0094 in.) . Maximum thrust clearance: 0.30 mm (0.0118 in.) . If the thrust clearance is greater than maximum, replace the thrust washers as a set. Thrust washer thickness: 2.430 - 2.480 mm (0.0957 - 0.0976 in.) . 22. Remove Crankshaft. a. Lift out the crankshaft. NOTE: Arrange the main bearings and thrust washers in the correct order.

b. Remove the 5 upper main bearings and 2 thrust washers from the cylinder block. 23. Check Fit Between Piston And Piston Pin. Try to move the piston back and forth on the piston pin. If any movement is felt, replace the piston and pin as a set.

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Fig. 229: Inspecting For Piston & Pin Slap Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 24. Remove Piston Rings. a. Using a piston ring expander, remove the 2 compression rings.

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Fig. 230: Removing Piston Rings Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE: Arrange the piston rings in the correct order only.

b. Remove the 2 side rails and oil ring by hand. 25. Disconnect Connecting Rod From Piston. a. Using a small screwdriver, pry out the 2 snap rings.

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Fig. 231: Removing Piston Pin Snap Ring Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Gradually heat the piston to 80 - 90C (176 - 194F).

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Fig. 232: Heating Pistons Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

The piston and pin are a matched set. Arrange the pistons, pins, rings, connecting rods and bearings in the correct order.

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Fig. 233: Removing Piston Pin Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Using a plastic-faced hammer and brass bar, lightly tap out the piston pin and remove the connecting rod. INSPECTION 1. Clean Cylinder Block. a. Remove the gasket material. Using a gasket scraper, remove all the gasket material from the top surface of the cylinder block.

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Fig. 234: Scraping Gasket Material From Cylinder Block Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE: If the cylinder is washed at high temperatures, the cylinder liner sticks out beyond the cylinder block, so always wash the cylinder block at a temperature of 45C (133F) or less.

b. Clean the cylinder block. Using a soft brush and solvent, thoroughly clean the cylinder block. 2. Inspect Cylinder Block. a. Inspect for flatness. Using a precision straight edge and a feeler gauge, measure the surface contacting the cylinder head gasket for warpage. Maximum warpage: 0.05 mm (0.0020 in.) . If warpage is greater than maximum, replace the cylinder block.

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Fig. 235: Inspecting Cylinder Block Warpage Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

b. Visually check the cylinder for vertical scratches. If deep scratches are present, replace the cylinder block.

Fig. 236: Inspecting Cylinder Block For Scratches Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Inspect the cylinder bore diameter. Using a cylinder gauge, measure the cylinder bore diameter at positions A, B and C in the thrust and axial directions.

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Fig. 237: Measuring Cylinder Bore Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Standard diameter: 79.000 - 79.013 mm (3.1102 - 3.1107 in.) . Maximum diameter: 79.013 mm (3.1107 in.) . If the diameter is greater than maximum, replace the cylinder block. 3. Remove Cylinder Ridge. If the wear is less than 0.2 mm (0.008 in.), using a ridge reamer, grind the top of the cylinder.

Fig. 238: Ridge Reaming Cylinders Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 4. Inspect 12 Pointed Head Bearing Cap Subassembly Bolts. : Using vernier calipers, measure the tension portion diameter of the bolt. Standard diameter: 7.3 - 7.5 mm (0.287 - 0.295 in.) . Minimum diameter: 7.3 mm (0.287 in.) . If the diameter is less than minimum, replace the bolt.

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Fig. 239: Measuring Diameter Of Bolts Tension Portion Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 5. Clean Piston. a. Using a gasket scraper, remove the carbon from the piston top.

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Fig. 240: Scraping Carbon From Piston Top Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Using a groove cleaning tool or a broken ring, clean the piston ring grooves.

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Fig. 241: Cleaning Piston Ring Grooves Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. CAUTION: Do not use a wire brush.

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Fig. 242: Cleaning Piston With Brush & Solvent Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Using a brush and solvent, thoroughly clean the piston. 6. Inspect Piston. a. Inspect the piston oil clearance. 1. Using a micrometer, measure the piston diameter at right angles to the piston pin center line, 25.6 mm (1.008 in.) from the piston head. Piston diameter: 78.925 - 78.935 mm (3.1073 - 3.1077 in.) .

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Fig. 243: Measuring Piston Diameter Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 2. Measure the cylinder bore diameter in the thrust directions. See step 2b). 3. Subtract the piston diameter measurement from the cylinder bore diameter measurement. Standard oil clearance: 0.065 - 0.088 mm (0.0026 - 0.0035 in.). Maximum oil clearance: 0.10 mm (0.0039 in.) . If the oil clearance is greater than maximum, replace all the 4 pistons. If necessary, replace the cylinder block. b. Inspect the piston ring groove clearance. Using a feeler gauge, measure the clearance between a new piston ring and the wall of the ring groove.

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Fig. 244: Measuring Ring Groove Clearance Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Ring groove clearance: 0.020 - 0.070 mm (0.0008 - 0.0028 in.) . If the clearance is not as specified, replace the piston. c. Inspect the piston ring end gap. 1. Insert the piston ring into the cylinder bore. 2. Using the piston, push the piston ring a little beyond the bottom of the ring travel, 110 mm (4.33 in.) from the top of the cylinder block.

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Fig. 245: Insperting Piston Ring For End Gap Measurement Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 3. Using a feeler gauge, measure the end gap.

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Fig. 246: Mesuring Piston Ring End Gap Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 247: Standard End Gap Chart Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Fig. 248: Maximum end gap Chart Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. If the end gap is greater than maximum, replace the piston ring. If the end gap is greater than maximum, even with a new piston ring, replace the cylinder block. d. Inspect the piston pin fit. At 80 - 90C (176 - 194F), you should be able to push the piston pin into the piston pin hole with your thumb.

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Fig. 249: Inspecting Piston Pin Fit Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 7. Inspect Connecting Rod. a. Using a rod aligner and a feeler gauge, check the connecting rod alignment. 1. Check for out-of-alignment. Maximum out-of-alignment: 0.05 mm (0.0020 in.) per 100 mm (3.94 in.) . If out-of-alignment is greater than maximum, replace the connecting rod assembly.

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Fig. 250: Inspecting Connecting Rod Angle Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 2. Check for twist. Maximum twist: 0.05 mm (0.0020 in.) per 100 mm (3.94 in.) . If twist is greater than maximum, replace the connecting rod assembly.

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Fig. 251: Inspecting Connecting Rod Twist Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Inspect the piston pin oil clearance. 1. Using a caliper gauge, measure the inside diameter of the connecting rod bushing. Bushing inside diameter: 20.012 - 20.021 mm (0.7879 - 0.7882 in.) .

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Fig. 252: Measuring Connecting Rod Bushing Internal Diameter Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 2. Using a micrometer, measure the piston pin diameter. Piston pin diameter: 20.004 - 20.013 mm (0.7876 - 0.7879 in.) . 3. Subtract the piston pin diameter measurement from the bushing inside diameter measurement. Standard oil clearance: 0.005 - 0.011 mm (0.0002 - 0.0004 in.) . Maximum oil clearance: 0.05 mm (0.0020 in.) . If the oil clearance is greater than maximum, replace the bushing. See step 1 under REPLACEMENT. If necessary, replace the piston and piston pin as a set.

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Fig. 253: Measuring Piston Pin Diameter Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 8. Inspect Connecting Rod Bolts. Using vernier calipers, measure the tension portion diameter of the bolt. Standard diameter: 6.6 - 6.7 mm (0.260 - 0.264 in.) . Minimum diameter: 6.4 mm (0.252 in.) . If the diameter is less than minimum, replace the bolt.

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Fig. 254: Measuring Connecting Rod Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 9. Inspect Crankshaft. a. Inspect for circle runout. 1. Place the crankshaft on V-blocks. 2. Using a dial indicator, measure the circle runout, as shown in the illustration. Maximum circle runout: 0.03 mm (0.0012 in.) . If the circle runout is greater than maximum, replace the crankshaft.

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Fig. 255: Measuring Crankshaft Runout Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Inspect the main journals and crank pins. 1. Using a micrometer, measure the diameter of each main journal and crank pin.

Fig. 256: Identifying Main Journal And Crank Pin Diameter Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Fig. 257: Inspecting main journals & crank pins Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. If the diameter is not as specified, check the oil clearance. See DISASSEMBLY. If necessary, replace the crankshaft. 2. Check each main journal and crank pin for taper and out-of-round as shown. Maximum taper and out-of-round: 0.02 mm (0.0008 in.) .

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

If the taper and out-of-round is greater than maximum, replace the crankshaft. REPLACEMENT 1. Replace Connecting Rod Bushings. a. Using SST and a press, press out the bushing. SST 09222-30010

Fig. 258: Removing Connecting Rod Bushing Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Align the oil hoses of a new bushing and the connecting rod. c. Using SST and a press, press in the bushing. SST 09222-30010

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Fig. 259: Locating Piston Pin Oil Hole Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. d. Using a pin hole grinder, hone the bushing to obtain the standard specified clearance (See page EM-74) between the bushing and piston pin.

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Fig. 260: Boring Piston Pin Hole Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. e. Check the piston pin fit at normal room temperature. Coat the piston pin with engine oil, and push it into the connecting rod with your thumb.

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Fig. 261: Testing Pistion Pin Fit Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 2. Replace crankshaft rear oil seal : If the rear oil seal is installed to the cylinder block: a. Using a knife cut off the oil seal lip. CAUTION: Be careful not to damage the crankshaft. Tape the screwdriver tip.

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Fig. 262: Removing Oil Seal With Screwdriver Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Using a screwdriver, pry out the oil seal. c. Apply MP grease to a new oil seal lip. d. Using SST and a hammer, tap in the oil seal until its surface is flush with the rear oil seal retainer edge. SST 09223-15030, 09950-70010 (09951-07100)

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Fig. 263: Installing Oil Seal Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REASSEMBLY NOTE:

Thoroughly clean all parts to be assembled. Before installing the parts, apply fresh engine oil to all sliding and rotating surfaces. Replace all gaskets, O-rings and oil seals with new parts.

1. Assemble Piston And Connecting Rod. NOTE: Be sure that end gap of the snap ring is not aligned with the pin hole cutout portion of the piston.

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Fig. 264: Installing Piston Pin Hole Snap Ring Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. a. Using a small screwdriver, install a new snap ring at one end of the piston pin hole. b. Gradually heat the piston to 80 - 90C (176 - 194F). c. Coat the piston pin with engine oil.

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Fig. 265: Heating Pistons Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. d. Align the front marks on the piston and connecting rod, and push in the piston with your thumb.

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Fig. 266: Align The Front Marks On The Piston And Connecting Rod Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE: Be sure that end gap of the snap ring is not as aligned with the pin hole cutout portion of the piston.

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Fig. 267: Installing Piston Pin Hole Snap Ring Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. e. Using a small screwdriver, install a new snap ring on the other end of the piston pin hole. 2. Install Piston Rings. a. Install the oil ring expander and 2 side rails by hand. b. Using a piston ring expander, install the 2 compression rings with the code mark facing upward. Code mark (No. 2 only): T or 2R .

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Fig. 268: Install Compression Rings & Locating Code Marks Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. CAUTION: Do not align the ring ends.

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Fig. 269: Positioning Piston Rings Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Position the piston rings so that the ring ends are as shown. 3. Install Connecting Rod Bearings. a. Align the bearing claw with the groove of the connecting rod or connecting cap. b. Install the bearings in the connecting rod and connecting rod cap.

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Fig. 270: Installing Bearing In Connecting Rod Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE: Upper bearings have an oil groove and oil holes; Lower bearings do not.

4. Install Main Bearings. NOTE: Install the bearing with the oil hole in the cylinder block.

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Fig. 271: Aligning Bearing Claw With Claw Groove Of Cylinder Block Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. a. Align the bearing claw with the claw groove of the cylinder block, and push in the 5 upper bearings. b. Align the bearing claw with the claw grove of the main bearing cap, and push in the 5 lower bearings.

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Fig. 272: Aligning Bearing Claw With Claw Grove Of Main Bearing Cap Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 5. Install The 2 Thrust Washers Under The No. 3 Journal Position Of The Cylinder Block With The Oil Grooves Facing Outward.

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Fig. 273: Installing Thrust Washers Under No. 3 Journal Of Cylinder Block Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 6. Place Crankshaft On Cylinder Block. . 7. Place Bearing Cap Subassembly On Cylinder Block. a. Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the bearing cap subassembly and cylinder block. Using a razor blade and gasket scraper, remove all the old packing (FIPG) material from the gasket surfaces and sealing grooves. throughly clean all components to remove all the loose material. Using a non-reusable solvent, clean both sealing surfaces. NOTE: Avoid applying an excessive amount to the surface.

b. Apply seal packing to the bearing cap subassembly as shown in the illustration. Seal packing: Part No. 08826-00080 or equivalent . Install a nozzle that has been cut to a 2 - 3 mm (0.08 - 0.12 in.) opening.

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Fig. 274: Locating Seal Packing Application Areas Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Parts must be assembled within 3 minutes of application. Otherwise the material must be removed and reapplied. Immediately remove nozzle from the tube and reinstall cap. c. Using a plastic-faced hammer, lightly tap the bearing cap subassembly to ensure a proper fit.

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Fig. 275: Ensuring proper fit Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 8. Install 12 Pointed Head Bearing Cap Subassembly Bolts. The bearing cap subassembly bolts are tightened in 3 progressive steps (steps (a), (b) and (d)). If any of the bearing cap subassembly bolts is broken or deformed, replace it. a. Apply a light coat of engine oil on the threads and under the bearing cap subassembly bolts. b. Install and uniformly tighten the 10 bearing cap subassembly bolts, in several passes, in the sequence shown. Torque: 22 N.m (225 kgf.cm, 16 ft.lbf) .

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Fig. 276: Identifying Bearing Cap Tightening Sequence Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Retighten the bearing cap subassembly bolts, in several passes, in the sequence shown. Torque: 44 N.m (449 kgf.cm, 32 ft.lbf) . If any of the bearing cap sub-assembly bolts does not meet the torque specification, replace the bearing cap subassembly bolt. d. Mark the front of the bearing cap subassembly bolts with paint. e. Retighten the bearing cap subassembly bolts by 45 and 45 in the numerical order shown.

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Fig. 277: Tightening Bearing Cap Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. f. Check that the painted mark is now at a 90 angle to the front. 9. Install Hexagon Head Bearing Cap Subassembly Bolts. a. Install and uniformly tighten the 10 bearing cap subassembly bolts in several passes. Torque: 18.5 N.m (189 kgf.cm, 14 ft.lbf) . b. Check that the crankshaft turns smoothly. 10. Check Crankshaft Thrust Clearance. See 21 in DASSASSEMBLY under CYLINDER BLOCK. 11. Install piston and connecting rod assembles : Using a piston ring compressor, push the correctly numbered piston and connecting rod assemblies into each cylinder with the front mark of the piston facing forward.

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Fig. 278: Using Piston Ring Compressor Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 12. Place Connecting Rod Cap On Connecting Rod. a. Match the numbered connecting rod cap with the connecting rod. b. Align the pin dowels of the connecting rod cap with the pins of the connecting rod, and install the connecting rod.

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Fig. 279: Aligning Pin Dowels Of Connecting Rod Cap With Pins Of Connecting Rod Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Check that the protrusion of the connecting rod cap is facing in the correct direction.

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Fig. 280: Locating Connecting Rod Cap Protrusion Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. CAUTION:

The connecting rod cap bolts are tightened in 2 progressive steps (steps (b) and (d)). If any of the connecting rod cap bolts is broken or deformed, replace it.

13. Install Connecting Rod Cap Bolts. a. Apply a light coat of engine oil on the threads and under the heads of the connecting rod cap bolts. b. Install and alternately tighten the 2 connecting rod cap bolts in several passes. Torque: 20 N.m (204 kgf.cm, 15 ft.lbf) . If any of the connecting rod cap bolts does not meet the torque specification, replace the connecting rod cap bolts.

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Fig. 281: Installing Connecting Rod Cap Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Mark the front of the connecting cap bolts with paint. d. Retighten the cap bolts by 90 as shown. e. Check that the painted mark is now at a 90 angle to the front.

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Fig. 282: Marking & Tightening Connecting Rod Cap Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. f. Check that the crankshaft turns smoothly. 14. Check Connecting Rod Thrust Clearance. See 17 In DISASSEMBLY Under CYLINDER BLOCK . NOTE: Wipe seal packing away from the contact surface of the cylinder block assembly and oil seal.

15. Install Rear Crankshaft Oil Seal. See Step 2 In Replacement. 16. Install a new gasket and the oil strainer with the 2 nuts and bolt.Torque: 9 N.m (92 kgf.cm, 80 in..lbf) . CAUTION: Do not use a solvent which will affect the painted surfaces.

17. Install Oil Pan. a. Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surface of the main bearing cap and oil pan. Using a razor blade and gasket scraper, remove all the old packing (FIPG) material from the gasket surfaces and sealing grooves.

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Thoroughly clean all components to remove all the loose material. Using a non-residue solvent, clean both sealing surfaces.

Fig. 283: Locating Oil Strainer Mounting Bolts & Nuts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE: Avoid applying an excessive amount to the surface.

b. Apply seal packing to the oil pan as shown in the illustration. Seal packing: Part No. 0882600080 or equivalent . Install a nozzle that has been cut to a 4 - 5 mm (0.16 - 0.20 in.) opening.

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Fig. 284: Identifying Seal Packing Applicaiton Points Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Parts must be assembled within 3 minutes of application. Otherwise the material must be remove and reapplied.

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Immediately remove nozzle from the tube and reinstall cap. c. Install the oil pan with the 14 bolts and 2 nuts. Uniformly tighten the bolts and nuts in several passes. Torque: 9 N.m (92 kgf.cm, 80 in..lbf) . 18. Install Oil Filter Union.

Torque: 30 N.m (306 kgf.cm, 21 ft.lbf) 19. Install Oil Filter . . 20. Install Oil Pump . .

Fig. 285: Locating Oil Pan Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 21. Install Engine Coolant Drain Union. a. Apply adhesive to 2 or 3 threads. Adhesive: Part No. 08833-00080, Three Bond 1344, LOCTITE 242 or equivalent .

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Fig. 286: Applying Adhesive To Drain Union Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE: After applying the specified torque, rotate the drain union clockwise until its drain port is facing downward.

b. Install the drain union. Torque: 20 N.m (200 kgf.cm, 14 ft.lbf) . 22. Install Knock Sensor. . Torque: 39 N.m (400 kgf.cm, 29 ft.lbf) 23. Install Thermostat. 24. Install Water Bypass Pipe. Torque: 9 N.m (92 kgf.cm, 80 in..lbf) . 25. Install Oil Dipstick And Guide. a. Install a new O-ring on the dipstick guide.

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Fig. 287: Locating Oil Dipstick Guide Mounting Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Apply soapy water on the O-ring. c. Connect the dipstick guide end to the main bearing cap. d. Install the dipstick guide with the bolt. Torque: 11 N.m (113 kgf.cm, 8 ft.lbf) . Install Engine Wire . Install Cylinder Head. See INSTALLATION. Install Timing Sprockets And Timing Chain. See INSTALLATION. Remove Engine Stand. . NOTE: The flywheel bolts are tightened in 2 progressive steps, () and (b).

26. 27. 28. 29.

30. M/T: Install Flywheel. a. Install and uniformly tighten the 8 mounting bolts, in several passes, in the sequence shown. Torque: 49 N.m (500 kgf.cm, 36 ft.lbf) .

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Fig. 288: Identifying Flywheel Bolt Tightening Sequence (M/T) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Mark the flywheel bolt with paint. c. Retighten the flywheel bolts by an additional 90. d. Check that the painted mark in now at a 90 angle to (a).

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Fig. 289: Marking Flywheel Bolts For Final Torque Turn. Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 31. A/T: Install Drive Plate. a. Install the front spacer, drive plate and rear plate on the crankshaft. b. Apply adhesive to 2 or 3 threads of the mounting bolt end, Adhesive: Part No. 08833-00070, Three Bond or equivalent .

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Fig. 290: Applying Adhesive to Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Install and uniformly tighten the 8 mounting bolts, in several passes, in the sequence shown. Torque: 83 N.m (850 kgf.cm, 61 ft.lbf) .

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Fig. 291: Identifying Drive Plate Bolt Tightening Sequence (M/T) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

ENGINE SPECIFICATIONS
GENERAL SPECIFICATIONS Application Displacement Bore Stroke Compression Ratio Fuel System VALVE CLEARANCE SPECIFICATIONS Application Intake Exhaust (1) Adjust valve clearance with engine cold. Specification 109 Cu. In. (1.8L) 3.11 in. (79.0 mm) 3.60 in. (91.5 mm) 10.0:1 SFI

(1) In. (mm)

.006-.010 (.15-.25) .010-.014 (.25-.35)

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS Application Crankshaft End Play Standard Wear Limit Runout Main Bearings

In. (mm)

.0016-.0094 (.040-.240) .0118 (.300) .0012 (.030)

Journal Diameter (1) Size Mark "0" 1.8897-1.8898 (47.998-48.000) Size Mark "1" 1.8896-1.8897 (47.996-47.998) Size Mark "2" 1.8895-1.8896 (47.994-47.996) Size Mark "3" 1.8894-1.8895 (47.992-47.994) Size Mark "4" 1.8893-1.8894 (47.990-47.992) Size Mark "5" 1.8892-1.8893 (47.988-47.990) Journal Out-Of-Round .0008 (.020) Journal Taper .0008 (.020) Oil Clearance Standard .0006-.0013 (.015-.032) Wear Limit .0020 (.050) Connecting Rod Bearings Journal Diameter 1.7320-1.7323 (43.992-44.000) Journal Out-Of-Round .0008 (.020) Journal Taper .0008 (.020) Oil Clearance Standard .0006-.0013 (.015-.032) Wear Limit .0020 (.050) (1) Main bearing journal diameter is determined by size mark on crankshaft counterweight. See Fig. 292. CONNECTING RODS Application Connecting Rod Small End Bore Diameter "A" "B" "C" Bore Diameter Pin Bushing Bore "A" "B" "C" Maximum Bend Maximum Twist Side Play Standard

In. (mm) .7879-.7880 (20.012-20.015) .7880-.7881 (20.016-20.018) .7881-.7882 (20.019-20.021) .7876-.7878 (20.006-20.009) .7878-.7879 (20.010-20.012) .7879-.7880 (20.013-20.015) .0020 Per 3.94 (.050 Per 100.0) .0020 Per 3.94 (.050 Per 100.0) .0063-.0135 (.160-.342)

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Wear Limit PISTONS, PINS & RINGS Application Pistons Oil Clearance Standard Maximum Diameter Pins Diameter "A" "B" "C" Piston Fit

.0135 (.342)

In. (mm)

.0026-.0035 (.065-.088) .0039 (.100) 3.1052-3.1091 (78.872-78.972)

.7876-.7877 (20.004-20.007) .7877-.7878 (20.008-20.010) .7878-.7879 (20.011-20.013)

(1)

Rod Fit Standard .0002-.0004 (.005-.011) Wear Limit .002 (.050) Rings No. 1 End Gap Standard .0098-.0138 (.250-.350) Wear Limit .0413 (1.050) Side Clearance .0012-.0028 (.030-.070) No. 2 End Gap Standard .0138-.0177 (.350-.450) Wear Limit .0472 (1.200) Side Clearance .0012-.0028 (.030-.070) No. 3 (Oil) End Gap Standard .0059-.0157 (.150-.400) Wear Limit .0413 (1.050) (1) Piston pin should slide into piston using thumb pressure after piston is heated to 176-194F (8090C). CYLINDER BLOCK Application Cylinder Bore Standard Diameter Main Bearing Bore Inside Diameter (1) Size Mark "0" Size Mark "1" Size Mark "2"

In. (mm) 3.1102-3.1107 (79.000-79.013) 2.0472-2.0473 (52.000-52.003) 2.0473-2.0474 (52.003-52.005) 2.0474-2.0475 (52.005-52.007)

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Size Mark "3" 2.0475-2.0476 (52.007-52.010) Size Mark "4" 2.0476-2.0477 (52.010-52.012) Size Mark "5" 2.0477-2.0478 (52.012-52.014) Size Mark "6" 2.0478-2.0479 (52.014-52.016) Maximum Deck Surface Warpage .0020 (.050) (1) Main bearing bore inside diameter is determined by size mark on cylinder block. See Fig. 292. OIL PUMP SPECIFICATIONS Application Driven Rotor-To-Oil Body Clearance Standard Wear Limit Rotor End Clearance Standard Wear Limit Rotor Tip Clearance Standard Wear Limit VALVES & VALVE SPRINGS Application Intake Valves Face Angle Minimum Margin Minimum Refinish Length Stem Diameter Valve Stem-To-Guide Oil Clearance Standard Maximum Exhaust Valves Face Angle Minimum Margin Minimum Refinish Length Stem Diameter Valve Stem-To-Guide Oil Clearance Standard Maximum Valve Springs Free Length Out-Of-Square Pressure Valve Closed

In. (mm) .0102-.0128 (.260-.325) .0128 (.325) .0010-.0028 (.025-.071) .0028 (.071) .0016-.0063 (.040-.160) .0063 (.160)

Specification 44.5 Degrees .028 in. (.70 mm) 3.4783 in. (88.350 mm) .2154-.2159 in. (5.470-5.485 mm) .0010-.0024 (.025-.060) .0031 (.08) 44.5 Degrees .028 in. (.70 mm) 3.4799 in. (88.390 mm) .2152-.2157 in. (5.465-5.480 mm) .0012-.0026 (.030-.065) .0031 (.08) 1.7087 in. (43.40 mm) .063 in. (1.60 mm) Lbs. @ In. (kg @ mm) 35.7-39.5 @ 1.323 (16.2-17.9 @ 33.60)

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Valve Open

75.4-83.3 @ .949 (34.2-37.8 @ 24.10)

CYLINDER HEAD Application Maximum Warpage Cylinder Block Surface Manifold Surface Valve Seats Intake & Exhaust Valves Seat Angle Seat Width Valve Guides Intake Valve Valve Guide Cylinder Head Bore I.D. Standard O/S Valve Guide I.D. Valve Guide Installed Height Exhaust Valve Valve Guide Cylinder Head Bore I.D. Standard O/S Valve Guide I.D. Valve Guide Installed Height CAMSHAFT Application End Play Standard Wear Limit Journal Diameter No. 1 All Others Lobe Height Intake Lobe Standard Wear Limit Exhaust Lobe

Specification .0020 in. (.050 mm) .0020 in. (.050 mm)

45 Degrees .039-.055 in. (1.00-1.40 mm)

.4049-.4057 in. (10.28510.306 mm) .4068-.4077 in. (10.33510.356 mm) .2169-.2177 in. (5.510-5.530 mm) .342-.358 in. (8.70-9.10 mm)

.4049-.4057 in. (10.28510.306 mm) .4068-.4077 in. (10.33510.356 mm) .2169-.2177 in. (5.510-5.530 mm) .342-.358 in. (8.70-9.10 mm)

In. (mm) .0016-.0037 (.040-.095) .0043 (.110) 1.3563-1.3569 (34.449-34.465) .9035-.9041 (22.949-22.965)

1.7454-1.7493 (44.333-44.433) 1.7394 (44.180)

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Standard Wear Limit Oil Clearance Standard Wear Limit VALVE LIFTERS Application Bore Diameter Lifter Diameter Oil Clearance Standard Maximum

1.7229-1.7268 (43.761-43.861) 1.7169 (43.610) .0006-.0020 (.014-.050) .0039 (.010)

In. (mm) 1.2205-1.2215 (31.000-31.025) 1.2191-1.2195 (30.966-30.976) .0009-.0023 (.024-.059) .0031 (.079)

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS Application Accessory Drive Belt Tensioner Bolt/Nut Bolt Nut A/C Compressor Bolt Axle Shaft Nut Ball Joint-To-Lower Control Arm Bolt/Nut Camshaft Bearing Cap Bolt Camshaft Sprocket Bolt Coolant Drain Union Connecting Rod Bolt Step 1 Step 2 Crankshaft Pulley Bolt Cylinder Head Bolt (2) Step 1 Step 2 Drive Belt Tensioner-To-Timing Chain Cover Bolt Nut Drive Belt Idler Pulley Drive Shaft Heat Insulator Bolt Engine Coolant Temperature Sensor Engine Hanger Bolt Exhaust Manifold Nut Ft. Lbs. (N.m) 51 (69) 21 (29) 18 (25) 166 (225) 105 (142)
(1)

40 (54) 14 (20) 15 (20) Additional 90 Degrees 102 (138) 36 (49) Additional 90 Degrees 51 (69) 21 (29) 32 (43) 13 (18) 15 (20) 28 (38) 27 (37)

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Exhaust Manifold Support Bracket Bolt Exhaust Pipe Flywheel/Drive Plate Bolt A/T M/T Step 1 Step 2 Front Exhaust Pipe-To-Center Exhaust Pipe Clamp Bolt Front Exhaust Pipe-To-Exhaust Manifold Bolt Front (Radiator Side) Engine Mount Bracket-To-Cylinder Block Bolt Front (Radiator Side) Engine Mount Through-Bolt/Nut Fuel Rail-To-Cylinder Head Bolt Generator Mounting Bolt Small Bolt Large Bolt Intake Manifold Bolt/Nut Intake Manifold Support Stay Bolt Knock Sensor Left Side Engine Mount Left (Transaxle Side) Engine Mount Through-Bolt/Nut Left (Transaxle Side) Engine Mount-To-Transaxle Bolt Main Bearing Cap Subassembly-To-Cylinder Block Bolt 12-Point Bolt (3) Step 1 Step 2 Step 3 Step 4 6-Point Bolt Oil Control Valve Filter Oil Filter Union Oil Pan Drain Plug Oxygen Sensor-To-Front Exhaust Pipe Nut Power Steering Gear Bolt Power Steering Pump Bolt/Nut Power Steering Pump Pulley Nut Rear Engine Mount-To-Transaxle Bolt Rear Engine Mount Bracket-To-Cylinder Block Bolt Rear Engine Mount Through-Bolt/Nut Rear Suspension Member Bolts Rear Suspension Upper Brace Bolts & Nuts Relief Valve Plug

36 (49) 32 (43) 65 (88) 36 (49) Additional 90 Degrees 24 (33) 46 (62) 57 (77) 64 (87) 14 (19) 18 (24) 40 (54) 14 (19) 18 (24) 29 (39) 59 (80) 64 (87) 48 (65)

16 (22) 32 (43) Additional 45 Degrees Additional 45 Degrees 14 (19) 22 (29) 22 (30) 27 (37) 15 (20) 33 (45) 27 (37) 32 (43) 47 (64) 57 (77) 64 (87) 38 (52) 59 (80) 27 (37)

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Right (Timing Chain Side) Engine Mount Bracket-To-Cylinder Block Bolt Right (Timing Chain Side) Engine Mount Insulator-To-Body Bolt Large Bolt Small Bolt Right (Timing Chain Side) Engine Mount Insulator-To-Engine Mount Bracket Bolt/Nut Bolt Nut Support Bracket-To-Left (Transaxle Side) Engine Mount Bolt Throttle Body Bolt/Nut Tie Rod-To-Steering Knuckle Nut Timing Chain Cover Bolt/Nut & Stud Bolt Timing Chain Tensioner Slipper Bolt Timing Chain Vibration Damper Valve Timing Controller Assembly Water Pump Bolt Wheel Lug Nut ABS Speed Sensor Bolt Camshaft Position Sensor Bolt Chain Tensioner-To-Timing Chain Cover Bolt Clutch Release Cylinder Bolt Coolant Bypass Pipe Coolant Inlet Housing Nut Crankshaft Position Sensor Bolt Fuel Pipe Clamp-To-Cylinder Head Bolt Heat Insulator-To-Exhaust Manifold Bolt Ignition Coil-To-Cylinder Head Bolt/Nut Oil Control Valve Oil Pan Baffle Oil Pan Bolt/Nut Oil Pressure Switch Oil Pump Body Cover Screw Oil Pump Pick-Up Tube Bolt/Nut Oil Pump-To-Cylinder Block Bolt Rockers-To-Cylinder Head Bolt Timing Chain Cover-To-Cylinder Head Bolts 10 mm Bolt 10 mm Nut Stud Timing Chain Cover-To-Cylinder Block Bolts 10 mm 12 mm Valve Cover Bolt/Nut (7)

35 (47) 47 (64) 38 (52) 47 (64) 38 (52) 15 (20) 15 (20) 36 (49)

(4)

14 (19) 8 (11) 40 (54)

(5)

76 (103) INCH Lbs. (N.m) 71 (8) 80 (9) 80 (9) 106 (12) 80 (9) 80 (9) 80 (9) 80 (9) 106 (12) 62 (7) 80 (9.0) 80 (9) 80 (9) 80 (9) 93 (10.5) 80 (9) 80 (9) 66 (7.5) 89 (10) 97 (11) 84 (9.5) 97 (11)
(6)

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

With Washer Without Washer Ventilation Pipe At Cylinder Head At Intake Manifold

80 (9) 97 (11) 89 (10)

(8)

Water Bypass Pipe 80 (9) (1) Tighten bolts to specification in sequence. See Fig. 293. Tighten bolts on front camshaft bearing cap to 17 ft. lbs. (23 N.m). Tighten bolts for all other camshaft bearing caps to 115 INCH lbs. (13.0 N.m). (2) Tighten bolts to specification in sequence. See Fig. 294.
(3) Tighten bolts to specification in sequence. See Fig. 295. (4) Tighten all bolts with 12-mm head to 14 ft. lbs. (19 N.m). Tighten bolt "A" with 10-mm head to

115 INCH lbs. (13 N.m). See Fig. 296. Tighten bolt "C" with 10-mm head to 80 INCH lbs. (9.0 N.m). Tighten all others to 97 INCH lbs. (11.0 N.m). (5) Tighten bolt "B" to 97 INCH lbs. (11.0 N.m) and bolt "C" to 80 INCH lbs. (9.0 N.m). See Fig. 296. (6) Tighten to 14 Ft. Lbs (18.5 N.m).
(7) Tighten bolts to specification in sequence. See Fig. 297. (8) Tighten to 18 Ft. Lbs (25 N.m).

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Fig. 292: Locating Cylinder Block, Crankshaft & Main Bearing Size Marks Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Fig. 293: Identifying Camshaft Bearing Cap Bolt Removal & Installation Sequence Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 294: Identifying Cylinder Head Bolt Removal & Installation Sequence Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Fig. 295: Identifying Main Bearing Cap Subassembly-To-Cylinder Block Bolt Removal & Installation Sequence

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 296: Identifying Timing Chain Cover & Water Pump Bolt Location & Length Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002-04 ENGINES Engine Mechanical - Corolla - 1.8L 4-Cylinder

Fig. 297: Identifying Valve Cover Bolt/Nut Installation Sequence Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2000-02 BRAKES Anti-Lock - Corolla

2000-02 BRAKES Anti-Lock - Corolla

DESCRIPTION
CAUTION: See ANTI-LOCK BRAKE SAFETY PRECAUTIONS article in GENERAL INFORMATION. Anti-Lock Brake System (ABS) consists of hydraulic unit, actuator, solenoids, pump motor, ABS Electronic Control Unit (ECU), relays, stoplight switch and wheel speed sensors. See Fig. 1 . An ABS warning light is located in instrument cluster. ABS warning light illuminates for 3 seconds as a bulb test when ignition is turned on. A primary check is performed after each engine start and when initial vehicle speed exceeds 6 MPH. Actuator noise is heard as vehicle is started or as speed exceeds 6 MPH. This is normal operation.

Fig. 1: Locating ABS Components Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE: For additional brake system information, see appropriate DISC & DRUM FWD CARS article.

2000-02 BRAKES Anti-Lock - Corolla

OPERATION
Under normal driving conditions, ABS functions as a standard brake system. With detection of wheel lockup, short pedal pulsations occurring in rapid succession will be felt in brake pedal. Pedal pulsation will continue until there is no longer a need for ABS function, or until vehicle is stopped. Maintaining a constant force on the brake pedal provides shortest stopping distance.

BLEEDING BRAKE SYSTEM

CAUTION: Brake fluid will damage painted surfaces. In case of contact, immediately rinse surface with water. NOTE: Use only DOT 3 brake fluid from a sealed container. DO NOT mix brake fluid types.

MASTER CYLINDER Ensure brake fluid reservoir is full. Disconnect brakelines from master cylinder. Have an assistant slowly depress brake pedal and hold. Block off outlet ports on master cylinder with finger, then have assistant release brake pedal. Repeat 3 or 4 times or until master cylinder is bled. BRAKELINES NOTE: Bleed brakes from farthest wheel first to closest wheel.

Install bleeder hose with container of clean brake fluid on wheel cylinder or caliper. Depress brake pedal several times and hold, then loosen bleeder valve. Tighten bleeder valve when fluid flow stops, then release brake pedal. Repeat until air bubbles are no longer present for each wheel. ABS ACTUATOR 1. Using fused jumper wires, connect terminals Tc, Ts and E1 together at Data Link Connector 1 (DLC1), located in engine compartment. See Fig. 2 . 2. Turn ignition on. ABS warning light should flash once every 1.5 seconds to indicate air bleed mode. Depress brake pedal one time and hold. After one second, pressure reduction solenoid should operate for 0.5 seconds, and brake pedal will reach end of it's travel. 3. Release brake pedal. After 0.5 seconds, ensure pump motor operates for 1.5 seconds. DO NOT depress brake pedal while pump motor is operating. Observe ABS warning light. If ABS warning light flashes once every second, turn ignition off. Bleed brakelines. See BRAKELINES . Go to next step. If ABS warning light flashes once every 2 seconds, repeat bleeding procedure beginning with step 1 . 4. Repeat steps 1 -3 several times. Repeat procedure for each wheel until air bubbles are no longer present. Remove jumper wires from DLC1. Ensure brake fluid reservoir is full.

2000-02 BRAKES Anti-Lock - Corolla

Fig. 2: Identifying Data Link Connector (DLC1) Terminals Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

TROUBLE SHOOTING
PRELIMINARY INSPECTION Begin diagnosis with a basic visual inspection of brake fluid level, tire size and other mechanical brake system components which may affect anti-lock operation. Check system sensors, wire harnesses and connectors for proper installation, routing and connection. Ensure all system fuses are okay. Repair as necessary. If cause of faulty operation cannot be located with basic diagnosis, ABS electronic control system must be checked. See SELF-DIAGNOSTIC SYSTEM . When ignition is turned on, ABS warning light should come on, then go out after 3 seconds. If ABS warning light does not operate as specified, go to ABS WARNING LIGHT under SYSTEM TESTS. SYMPTOM DIAGNOSIS

2000-02 BRAKES Anti-Lock - Corolla

Perform symptom diagnosis when no DTCs are present, but symptom still occurs. See SYMPTOM DIAGNOSIS table, then see specified procedure or appropriate test under SELF-DIAGNOSTIC SYSTEM , DIAGNOSTIC TESTS or SYSTEM TESTS . Perform appropriate test or procedure as directed. SYMPTOM DIAGNOSIS Symptom/Circuit (1) ABS Does Not Operate (2) Check DTC, Confirm Normal DTC Is Output DTC Or Procedure RETRIEVING DIAGNOSTIC TROUBLE CODES DTC 41 DTC 31-34 Visual Inspection RETRIEVING DIAGNOSTIC TROUBLE CODES DTC 31-34 DTC 49 Visual Inspection ABS WARNING LIGHT ABS LIGHT ALWAYS ON: ECU MALFUNCTION ABS WARNING LIGHT Tc TERMINAL Ts TERMINAL ABS LIGHT ALWAYS ON: ECU MALFUNCTION

IG Power Source Circuit Speed Sensor Circuit Check Hydraulic Circuit For Leaks ABS Does Not Operate Intermittently(2) Check DTC, Confirm Normal DTC Is Output

Speed Sensor Circuit Stoplight Switch Circuit Check Hydraulic Circuit For Leaks ABS Warning Light Abnormal ABS Warning Light Circuit ABS ECU Unable To Perform DTC Check (2) ABS Warning Light Circuit Tc Terminal Circuit Unable To Check Speed Sensor Signal Ts Terminal Circuit Check ABS ECU Circuits
(1) Check circuits in order given.

(2) If all circuits check okay and problem is still occurring, replace ABS ECU.

SELF-DIAGNOSTIC SYSTEM
RETRIEVING DIAGNOSTIC TROUBLE CODES NOTE: Speed sensor diagnostics and code retrieval use different Data Link Connector No. 1 (DLC1) terminals. If a speed sensor circuit problem is suspected, see WHEEL SPEED SENSOR DIAGNOSTICS .

ABS Warning Light Diagnostics

2000-02 BRAKES Anti-Lock - Corolla

1. Ensure battery is fully charged. Turn ignition on. ABS warning light should illuminate, then turn off after 3 seconds. If ABS warning light does not illuminate, check fuse, bulb, and wiring harness. See ABS WARNING LIGHT CIRCUIT under SYSTEM TESTS. 2. Using a fused jumper wire, jumper DLC1 terminals Tc and E1. See Fig. 2 . If a malfunction is detected, 4 seconds will elapse and ABS warning light will begin to flash a 2-digit DTC. First number of flashes equal first digit in DTC. After a 1.5-second pause, second number of flashes equal second digit in DTC. 3. If 2 or more DTCs are stored, there will be a 2.5-second pause between each DTC. After all DTCs are flashed, there will be a 4 second pause and all DTCs will repeat. If ABS system is functioning properly, ABS warning light will flash 2 times per second. For DTC definitions, see DIAGNOSTIC TROUBLE CODE DEFINITIONS . For diagnostic testing procedures, see DIAGNOSTIC TESTS . CLEARING DIAGNOSTIC TROUBLE CODES Using a fused jumper wire, jumper DLC1 terminals Tc and E1. See Fig. 2 . Turn ignition on. Depress brake pedal 8 or more times within 5 seconds. DTCs are now cleared. Ensure ABS warning light flashes 2 times per second. Remove jumper wire. Ensure ABS warning light turns off. Reconnect short pin.

DIAGNOSTIC TROUBLE CODE DEFINITIONS

DIAGNOSTIC TROUBLE CODE DEFINITIONS DTC ABS-Related DTCs (1) 11 12 13 14 21 22 23 24 31 32 33 34 41 49 51 ABS ECU MALFUNCTION Open In ABS Solenoid Relay Circuit Short In ABS Solenoid Relay Circuit Open In ABS Pump Motor Relay Circuit, Defective Pump Motor Short In ABS Pump Motor Relay Circuit, Defective Pump Motor SRH1 Or SRR Solenoid Valve Faulty SLH1 Or SLR Solenoid Valve Faulty SLH2 Or SLR Solenoid Valve Faulty SRH2 Or SRR Solenoid Valve Faulty Malfunction In RF Speed Sensor Signal Malfunction In LF Speed Sensor Signal Malfunction In RR Speed Sensor Signal Malfunction In LR Speed Sensor Signal Excessively Low Battery Voltage Open Stoplight Switch Circuit, Defective Stoplight Switch Pump Motor Locked Up Malfunction In ABS ECU Circuit/Malfunction

2000-02 BRAKES Anti-Lock - Corolla

Speed Sensor-Related DTCs (2) 71 72 73 74 75

RF Speed Sensor Signal Low Voltage LF Speed Sensor Signal Low Voltage RR Speed Sensor Signal Low Voltage LR Speed Sensor Signal Low Voltage RF Speed Sensor Abnormal Change In Output Voltage 76 LF Speed Sensor Abnormal Change In Output Voltage 77 RR Speed Sensor Abnormal Change In Output Voltage 78 LR Speed Sensor Abnormal Change In Output Voltage (1) For ABS ECU DTCs, connect jumper wire between terminals Tc and E of DLC1. 1
(2) For speed sensor DTCs, connect jumper wire between terminals Ts and E of DLC1. 1

SPEED SENSOR DIAGNOSTICS NOTE: During wheel speed sensor diagnosis, ABS functions like a standard brake system.

1. Ensure battery is fully charged. Turn ignition on. Verify ABS warning light illuminates, then turns off after 3 seconds. If ABS warning light does not illuminate, check fuse, bulb, and wiring harness. See ABS WARNING LIGHT CIRCUIT under SYSTEM TESTS. 2. Turn ignition off. Connect a fused jumper wire between DLC1 terminals Ts and E1. See Fig. 2 . Apply parking brake. Start engine. DO NOT press brake pedal. ABS warning light should flash 4 times per second. 3. Drive vehicle at speeds greater than 28 MPH for several seconds. Stop vehicle. Connect an additional fused jumper wire between DLC1 terminals Tc and E1, leaving terminals Ts and E1 connected. 4. If a DTC is stored, 4 seconds will elapse, then ABS warning light will begin to flash a 2-digit DTC. First group of flashes indicate first digit in DTC. After a 1.5-second pause, second group of flashes indicate second digit in a DTC. 5. If 2 or more DTCs are stored, there will be a 2.5-second pause between each DTC. After all DTCs are flashed, there will be a 4-second pause, then all DTCs will repeat. 6. Record DTCs. Turn ignition off. Repair as necessary. See DIAGNOSTIC TROUBLE CODE DEFINITIONS . See FRONT SPEED SENSORS , REAR SPEED SENSORS and SENSOR ROTORS under COMPONENT TESTS. Clear DTCs. See CLEARING DTCS .

DIAGNOSTIC TESTS
NOTE: For identification of ABS ECU terminals and circuits, see Fig. 4 Also see WIRING DIAGRAMS .

DTC 11 & DTC 12: ABS SOLENOID RELAY CIRCUIT

2000-02 BRAKES Anti-Lock - Corolla

Circuit Description

ABS solenoid relay supplies power to each ABS solenoid. After ignition switch is turned to ON position, if initial check is okay, relay is energized. If malfunction occurs in ABS relay circuit, ABS ECU cuts off current to ABS solenoid valve relay and prohibits ABS control.
DTC Detecting Condition

Detection of any of the following conditions may set DTC 11:

With ABS ECU terminal IG1 voltage at 9.5-18.5 volts and ABS solenoid relay energized, relay contact OFF condition is detected for 0.2 seconds or more. Immediately after ignition switch is turned to ON position and ABS solenoid relay is de-energized, relay contact ON condition is detected for 0.2 seconds or more.

Diagnostic Procedure

1. Turn ignition off. Disconnect ABS ECU harness connector. Using DVOM, measure voltage between terminals No. 15 (Black/Yellow wire) and No. 8 (White/Black wire), then No. 23 (White/Black wire). See Fig. 4 . If voltage is 10-14 volts, go to next step. If voltage is not 10-14 volts, check and repair fuses and/or wiring harness as necessary. See WIRING DIAGRAMS . 2. Measure voltage between terminals No. 9 (Red wire) and No. 8 (White/Black wire), then No. 23 (White/Black wire). If voltage is 10-14 volts, go to next step. If voltage is not 10-14 volts, check and repair fuses and/or wiring harness as necessary. See WIRING DIAGRAMS . 3. Reconnect all harness connectors. Clear DTCs. See CLEARING DTCS under SELF-DIAGNOSTIC SYSTEM. Test drive vehicle. If DTC 11 or 12 sets, check condition of all wiring harness and component connections. If connections are okay, ABS ECU may be faulty. DTC 13 & DTC 14: ABS MOTOR RELAY CIRCUIT
Circuit Description

ABS motor relay supplies power to ABS pump motor. While ABS is activated, ABS ECU switches ABS motor relay on and operates ABS pump motor. If malfunction occurs in ABS motor relay circuit, ABS ECU cuts off current to ABS solenoid valve relay and prohibits ABS control.
DTC Detecting Condition

Detection of any of the following conditions may set DTC 13:

When pump motor relay is on, relay contact OFF condition is detected for 0.2 seconds or more. When pump motor relay is energized, relay contact OFF condition is detected for 0.5 seconds or more.

Detection of any of the following conditions may set DTC 14:

When pump motor relay is off, relay contact ON condition is detected for 0.2 seconds or more. When pump motor relay is turned off, relay contact ON condition is detected for 2 seconds or more.

Diagnostic Procedure

2000-02 BRAKES Anti-Lock - Corolla

1. Turn ignition off. Disconnect ABS ECU harness connector. Using DVOM, measure voltage between terminals No. 9 (Red wire) and No. 8 (White/Black wire), then between No. 24 (Red wire) and No. 23 (White/Black wire). See Fig. 4 . If voltage is 10-14 volts on both circuits, go to next step. If voltage is not 10-14 volts, check and repair fuses and/or wiring harness as necessary. See WIRING DIAGRAMS . 2. Reconnect all harness connectors. Clear DTCs. See CLEARING DTCS under SELF-DIAGNOSTIC SYSTEM. Test drive vehicle. If DTCs 13 or 14 set, check condition of all wiring harness and component connections. If connections are okay, ABS ECU may be faulty. DTC 21, DTC 22, DTC 23 & DTC 24: ABS SOLENOID VALVE CIRCUIT
Circuit Description

ABS solenoid turns on when signals are received from ABS ECU and controls pressure acting on calipers/wheel cylinders, thus controlling braking force. If malfunction occurs in actuator solenoid valve circuit, ABS ECU cuts off current to ABS solenoid valve relay and prohibits ABS control. DTC 21 is for right front solenoid valve, DTC 22 is for left front solenoid valve, DTC 23 is for right rear solenoid valve and DTC 24 is for left rear solenoid valve.
DTC Detecting Condition

Detection of any of the following conditions may set DTCs 21-24:

With ABS ECU terminal IG1 voltage at 9.5-18.5 volts, open or short detected in solenoid circuit for 0.5 second or more.

Diagnostic Procedure

Clear DTCs. See CLEARING DTCS under SELF-DIAGNOSTIC SYSTEM. Turn ignition off. Turn ignition on, then recheck for DTCs. If same DTCs are present, replace ABS actuator assembly. If no DTCs are present, system is okay at this time. DTC 31, DTC 32, DTC 33, DTC 34: SPEED SENSOR CIRCUIT
Circuit Description

Speed sensor detects wheel speed and sends appropriate signals to ABS ECU. These signals are used to control ABS system. Front and rear sensor rotors each have 48 teeth. When rotor rotates, magnetic field emitted by permanent magnet in speed sensor generates an AC voltage. Since frequency of this AC voltage changes in direct proportion to speed of rotor, frequency is used by ABS ECU to detect speed of each wheel. If malfunction occurs in speed sensor circuit, ABS ECU cuts off current to ABS solenoid valve relay and prohibits ABS control. DTC 31 is for right front sensor, 32 is for left front sensor, 33 is for right rear sensor and 34 is for left rear sensor.
DTC Detecting Condition

Detection of any of the following conditions may set DTCs 31-34:

2000-02 BRAKES Anti-Lock - Corolla

Vehicle speed is greater than 6 MPH and pulses are not input for 15 seconds or more. Momentary interruption of speed sensor signal occurs at least 7 times or more between ignition on and ignition off. Abnormal speed sensor signal generated noise for 5 seconds or more with vehicle speed at 12 MPH or greater. Speed sensor signal circuit open for 0.3 seconds or more.

Diagnostic Procedure

NOTE:

For DTCs 31 or 32 (front speed sensor), go to step 1 . For DTCs 33 or 34 (rear speed sensor), go to step 2 .

1. Disconnect front wheel speed sensor harness connector. See FRONT WHEEL SPEED SENSORS under REMOVAL & INSTALLATION. Measure resistance between wheel speed sensor terminals. Resistance should be 1.4-1.8 k/ohms. Measure resistance between chassis ground and each wheel speed sensor terminal. Resistance should be one megohm or greater. If resistance is as specified, go to step 3 . If resistance is not as specified, replace wheel speed sensor. 2. Disconnect rear wheel speed sensor harness connector. See REAR WHEEL SPEED SENSORS under REMOVAL & INSTALLATION. Using DVOM, measure resistance between wheel speed sensor terminals. Resistance should be 0.9-1.3 k/ohms. Measure resistance between ground and each wheel speed sensor terminal. Resistance should be one megohm or greater. If resistance is as specified, go to next step. If resistance is not as specified, replace wheel speed sensor. 3. Check for open or short circuit in wiring harness between affected wheel speed sensor and ABS ECU. See WIRING DIAGRAMS . Repair as necessary. If wiring harness is okay, go to next step. 4. If oscilloscope is available, check speed sensor signal wave form. Remove ABS ECU. Do not disconnect electrical connectors. Connect oscilloscope between GND terminal and terminals FR+, FL+, RR+ and RL+ at ABS ECU connector. See Fig. 4 . Drive vehicle at 12 MPH and observe signal wave form. Signal should be smooth and consistent without any irregular wave forms. If wave form is smooth and consistent, replace ABS ECU. If wave form is not smooth and consistent, go to next step. 5. Check wheel speed sensor in question for proper installation. Check sensor rotors for damage. Axle hubs and/or axle shafts must be removed for sensor rotor inspection. See following: For 2000 models, see AXLE SHAFTS - FWD in DRIVELINE/AXLES. For 2001 models, see FWD AXLE SHAFTS in DRIVELINE/AXLES. For 2002 models, see AXLE SHAFTS - COROLLA in DRIVELINE/AXLES. Also see appropriate DISC & DRUM - FWD CARS article in MECHANICAL-HYDRAULIC BRAKES. Repair as necessary. If no problem is found, replace ABS ECU. See ABS ACTUATOR/ECU under REMOVAL & INSTALLATION. DTC 41: IG POWER SOURCE CIRCUIT
Circuit Description

IG power source circuit is power source for ABS ECU and ABS actuator solenoids. If malfunction occurs in power source circuit, ABS ECU cuts off current to ABS solenoid valve relay and prohibits ABS control.
DTC Detecting Condition

Detection of any of the following conditions may set DTC 41:

2000-02 BRAKES Anti-Lock - Corolla

With vehicle speeds at 1.9 MPH or greater, voltage at terminals No. 9 (Red wire) or 15 (Black/Yellow wire) of ABS ECU is 9.5 volts or less for 10 seconds or more. With voltage at terminal No. 15 (Black/Yellow wire) of ABS ECU at 9.5 volts or less, solenoid relay open, pump motor relay open, solenoid fault detecting conditions are established.

Diagnostic Procedure

1. Ensure battery and charging system are okay. If voltage at battery is 10-14 volts, go to next step. If voltage is not 10-14 volts, repair charging system. Ensure system fuses are okay. 2. Disconnect ABS ECU harness connector. Turn ignition on. Using DVOM, measure voltage between terminal No. 15 (Black/Yellow wire) and No. 8 (White/Black wire), then terminal No. 23 (White/Black wire) at ABS ECU harness connector. See Fig. 4 . If voltage is 10-14 volts, replace ABS actuator assembly. See ABS ACTUATOR/ECU under REMOVAL & INSTALLATION. If voltage is not 10-14 volts, go to next step. 3. Turn ignition off. Measure resistance between chassis ground and terminals No. 8 (White/Black wire) and No. 23 (White/Black wire) at ABS ECU harness connector. See Fig. 4 . If resistance is one ohm or less, go to next step. If resistance is greater than one ohm, repair high resistance or open circuit in wiring. See WIRING DIAGRAMS . 4. Remove and inspect ECU-IG fuse (10-amp) from underdash fuse block. If fuse is blown, check for short circuit in wiring harness between ABS ECU and ECU-IG fuse. See WIRING DIAGRAMS . Repair as necessary. If fuse is okay, check for open circuit in wiring harness between ABS ECU and battery. Repair as necessary. DTC 49: STOPLIGHT SWITCH CIRCUIT
Circuit Description

Stoplight switch senses whether brake pedal is depressed or released, and sends signal to ABS ECU for ABS control.
DTC Detecting Condition

If voltage at ABS ECU terminal No. 15 (IG circuit) is 9.5-18.5 volts and ABS is in non-operation, an open in stoplight switch circuit for 0.3 second or more will set DTC 49.
Diagnostic Procedure

1. Ensure stoplights illuminate when brake pedal is depressed, and turn off when released. If operation is as specified, go to next step. If operation is not as specified, repair stoplight circuit. See WIRING DIAGRAMS . 2. Disconnect ABS ECU harness connector. Using DVOM, measure voltage between chassis ground and terminal No. 5 (Green/White wire) at ABS ECU harness connector. See Fig. 4 . Depress brake pedal. If voltage is 8-14 volts, replace ABS actuator assembly. See ABS ACTUATOR/ECU under REMOVAL & INSTALLATION. If voltage is not 8-14 volts, go to next step. 3. Check for open circuit in wiring harness between ABS ECU and stoplight switch. See WIRING DIAGRAMS . Repair as necessary. If no problem is found, perform next logical circuit check listed in SYMPTOM DIAGNOSIS . See SYMPTOM DIAGNOSIS under TROUBLE SHOOTING. DTC 51: ABS PUMP MOTOR LOCK

2000-02 BRAKES Anti-Lock - Corolla

Circuit Description

During ABS pump motor malfunction, ABS ECU cuts off current to ABS solenoid valve relay and prohibits ABS control.
DTC Detecting Condition

If ABS actuator pump motor is not operating normally during initial check, DTC 51 may set. Suspect ABS pump motor.
Diagnostic Procedure

Replace ABS pump motor. DTC 71, DTC 72, DTC 73 & DTC 74: LOW OUTPUT VOLTAGE FROM SPEED SENSOR
Circuit Description & Detecting Conditions

DTC 71 Right Front Speed Sensor DTC 72 Left Front Speed Sensor DTC 73 Right Rear Speed Sensor DTC 74 Left Rear Speed Sensor For DTCs 71-74, an abnormally low output voltage has been detected from speed sensor. Check the following:

Right front, left front, right rear, and left rear speed sensors Sensor installation Sensor rotors

DTC 75, DTC 76, DTC 77 & DTC 78: ABNORMAL CHANGE IN SPEED SENSORS
Circuit Description & Detecting Conditions

DTC 75 Right Front Speed Sensor DTC 76

2000-02 BRAKES Anti-Lock - Corolla

Left Front Speed Sensor DTC 77 Right Rear Speed Sensor DTC 78 Left Rear Speed Sensor For DTCs 75-78, an abnormal change in output voltage was detected by the speed sensors. Check the following:

Right front speed sensor rotors Left front speed sensor rotors Right rear speed sensor rotors Left rear speed sensor rotors

SYSTEM TESTS
SYSTEM TEST INDEX Symptom ABS ECU Malfunction ABS Warning Light Tc Terminal Ts Terminal TEST A: ABS ECU MALFUNCTION
Circuit Description

Perform Test A B C D

During power source circuit fault, ABS ECU cuts off current to ABS solenoid valve relay and prohibits ABS control.
DTC Detecting Condition

ABS ECU internal malfunction has been detected. ABS ECU connector terminal No. 15 (Black/Yellow wire) voltage is 7 volts or less.

Diagnostic Procedure

Diagnostic information is not available from manufacturer. See WIRING DIAGRAMS . TEST B: ABS WARNING LIGHT
Circuit Description

If ABS ECU detects a system malfunction, ABS ECU illuminates ABS warning light while at the same time prohibiting ABS control. At this time, ABS ECU records a DTC in memory. Connecting terminals Tc and

2000-02 BRAKES Anti-Lock - Corolla

E1 of DLC1 in engine compartment causes ABS warning light to flash and output a DTC. See Fig. 2 .
Diagnostic Procedure

1. If ABS warning light remains illuminated, go to next step. If ABS warning light does not illuminate, check light bulb and replace as necessary. If bulb is okay, diagnose combination meter (instrument cluster). See following: For 2000 models, see INSTRUMENT PANELS article in ACCESSORIES & EQUIPMENT. For 2001 models, see INSTRUMENT PANELS article in ACCESSORIES & EQUIPMENT. For 2002 models, see appropriate INSTRUMENT PANELS article in ACCESSORIES & EQUIPMENT. If combination meter is okay, check for open circuit in wiring harness between GAUGE fuse (10amp) and ABS ECU. See WIRING DIAGRAMS . Repair as necessary. 2. Retrieve DTCs. See RETRIEVING DTCS . If a DTC is present, perform appropriate test under DIAGNOSTIC TESTS . If no DTCs are present, check for short circuit in wiring harness between ABS warning light, DLC1 and ABS ECU. See WIRING DIAGRAMS . Repair as necessary. TEST C: TC TERMINAL
Circuit Description

Connecting terminals Tc and E1 of DLC1 in engine compartment starts DTC check. See Fig. 2 .
Diagnostic Procedure

Turn ignition on. Using DVOM, measure voltage between terminals Tc and E1 of DLC1 in engine compartment. If voltage is 10-14 volts, circuit is okay. If ABS warning light does not flash even after terminals are connected, malfunction may exist in ABS ECU. If voltage is not 10-14 volts, check for open or short circuit in wiring harness between ABS ECU and DLC1, or between chassis ground and DLC1. See WIRING DIAGRAMS . Repair as necessary. If wiring harness is okay, replace ABS ECU. See ABS ACTUATOR/ECU under REMOVAL & INSTALLATION. TEST D: TS TERMINAL
Circuit Description

Sensor check circuit detects abnormalities in speed sensor signal which cannot be detected when checking for DTCs. Connecting terminals Ts and E1 of DLC1 in engine compartment starts sensor circuit check. See Fig. 2 .
Diagnostic Procedure

Turn ignition on. Using DVOM, measure voltage between terminals Ts and E1 of DLC1. If voltage is 10-14 volts, circuit is okay. If ABS warning light does not flash even after terminals are connected, malfunction may exist in ABS ECU. If voltage is not 10-14 volts, check for open or short circuit in wiring harness between ABS ECU and DLC1, or between chassis ground and DLC1. See WIRING DIAGRAMS . Repair as necessary. If wiring harness is okay, replace ABS ECU. See ABS ACTUATOR/ECU under REMOVAL & INSTALLATION.

COMPONENT TESTS

2000-02 BRAKES Anti-Lock - Corolla

FRONT SPEED SENSORS 1. Remove front fender liner. Disconnect speed sensor connector. Measure resistance between speed sensor terminals. Resistance should be 1.4-1.8 k/ohms. 2. Measure resistance between each sensor terminal and sensor body. Resistance should be one megohm or more. If resistance is not as specified, replace speed sensor. REAR SPEED SENSORS 1. Remove rear seat cushion. Disconnect speed sensor connector. Measure resistance between speed sensor terminals. Resistance should be 0.9-1.3 k/ohms. 2. Measure resistance between each sensor terminal and sensor body. Resistance should be one megohm or more. If resistance is not as specified, replace speed sensor. SENSOR ROTORS Visually inspect sensor rotor serrations for scratches, cracks, missing teeth, or warping. Replace front drive axle shaft or rear hub as necessary if rotor is damaged.

REMOVAL & INSTALLATION

WARNING: Hydraulic system may be under high pressure. Use caution when opening hydraulic system. ABS ACTUATOR/ECU
Removal & Installation

Disconnect ABS actuator and ECU electrical connector lock. See Fig. 3 . Disconnect harness connector. Remove brake lines. Remove 3 retaining nuts, then remove ABS actuator and ECU. To install, reverse removal procedure. Fill fluid reservoir, then bleed brake system. See BLEEDING BRAKE SYSTEM .

2000-02 BRAKES Anti-Lock - Corolla

Fig. 3: Exploded View Of ABS Actuator & ECU Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. FRONT & REAR WHEEL SPEED SENSOR ROTORS
Removal & Installation

Front sensor rotor is attached to front drive axle. For drive axle removal and installation procedure, see following:

2000-02 BRAKES Anti-Lock - Corolla

For 2000 models, see AXLE SHAFTS - FWD in DRIVELINE/AXLES. For 2001 models, see FWD AXLE SHAFTS in DRIVELINE/AXLES. For 2002 models, see AXLE SHAFTS - COROLLA in DRIVELINE/AXLES.

Rear sensor rotor is attached to rear axle hub. Remove 4 hub bolts and remove rear axle hub. Replace rear sensor rotor as necessary. To install, reverse removal procedure. Tighten hub bolts to specification. See TORQUE SPECIFICATIONS . FRONT WHEEL SPEED SENSORS
Removal & Installation

1. Raise and support front of vehicle. Remove front wheel. Remove inner fender liner. Disconnect wheel speed sensor harness connector. Remove 3 clamp bolts holding sensor harness to vehicle body and strut assembly. 2. Remove wheel speed sensor mounting bolt. Remove wheel speed sensor from steering knuckle. To install, reverse removal procedure. Tighten wheel speed sensor mounting bolt to specification. See TORQUE SPECIFICATIONS . REAR WHEEL SPEED SENSORS
Removal & Installation

1. Remove rear seat cushion and seat back. Remove lower center garnish, rear door scuff plate and room partition trim. Disconnect wheel speed sensor harness connector. Pull out sensor wire harness with grommet. Remove 2 clamp bolts holding sensor harness to vehicle body and strut assembly. 2. If necessary, remove rear axle hub. Remove wheel speed sensor. To install, reverse removal procedure. Tighten wheel speed sensor and brake components to specification. See TORQUE SPECIFICATIONS .

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS Application ABS Actuator & ECU Mounting Nuts Brakeline Fittings Brake Pedal Pushrod Lock Nut Rear Axle Hub Bolts Wheel Lug Nuts Master Cylinder Mounting Nuts Wheel Speed Sensor Harness Clamp Bolt Front Rear Wheel Speed Sensor Mounting Bolt Ft. Lbs. (N.m) 16 (22) 11 (15) 19 (26) 59 (80) 76 (103) INCH Lbs. (N.m) 115 (13.0) 44 (5.0) 71 (8.0) 71 (8.0)

ABS ECU PIN VOLTAGES

2000-02 BRAKES Anti-Lock - Corolla

Remove ABS ECU, leaving harness connectors connected. Using DVOM, measure voltage in appropriate circuits by backprobing ABS ECU harness connectors. See Fig. 4 . Ensure voltage is within specification under specified conditions.

Fig. 4: ABS ECU Standard Values Chart Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

WIRING DIAGRAMS
2000 For 2000 models, go to ANTI-LOCK BRAKES in SYSTEM WIRING DIAGRAMS article in ELECTRICAL. 2001 For 2001 models, go to ANTI-LOCK BRAKES in SYSTEM WIRING DIAGRAMS article in ELECTRICAL. 2002 For 2002 models, go to ANTI-LOCK BRAKES in SYSTEM WIRING DIAGRAMS article in ELECTRICAL.

SYSTEM WIRING DIAGRAMS Fig. 3: Anti-lock Brake Circuits

SYSTEM WIRING DIAGRAMS Fig. 4: Anti-lock Brake Circuits

2002 AXLE SHAFTS FWD Axle Shafts - Corolla

2002 AXLE SHAFTS FWD Axle Shafts - Corolla

DESCRIPTION
Axle shafts transfer power from transaxle to front wheels. All axle shafts consist of a shaft with flexible Constant Velocity (CV) joints at each end. Inner CV joint is splined or bolted to transaxle. Outer CV joint is splined to hub assembly, and secured by axle shaft nut. The inner CV joint is a plunging tripod joint. The plunging action allows for axle shaft length change as suspension moves up and down. The inner and outer CV joints are enclosed by a CV joint boot. The boot maintains lubrication in the joint and prevents contamination of CV lubricant. Boots must be replaced when signs of leakage or cracks are present. The inner CV joint can be repaired without replacing assembly. The outer CV joint must be replaced as an assembly.

REMOVAL & INSTALLATION

NOTE: Manufacturer recommends removing right axle shaft and intermediate shaft (if equipped) as an assembly.

COROLLA
Removal

1. 2. 3. 4. 5. 6. 7. 8. 9. 10.

Raise and support vehicle. Remove front wheels. Remove lower engine covers. Drain transaxle fluid into proper container. Disconnect ABS speed sensor (if applicable). Remove cotter pin and axle shaft lock nut cap. Apply brakes, and remove axle shaft bearing lock nut. Disconnect tie rods from steering knuckle. Disconnect lower ball joint from lower control arm. Using a plastic hammer, separate axle shaft from bearing hub. Use a hammer and hub nut wrench to separate axle shaft from transaxle. Use caution to prevent damage to speed sensor serrations on axle shaft. 11. Remove snap ring.

Inspection

1. Ensure no play exists in inboard and outboard joints. 2. Inboard joint must slide smoothly in thrust direction and be free from excessive play in radial direction. 3. Check for torn or damaged boots.

2002 AXLE SHAFTS FWD Axle Shafts - Corolla

Disassembly

1. Remove CV joint boot clamps, and slide boots away from joint. 2. Paint alignment marks on CV joint housings, tripod and shaft(s) for reassembly reference. DO NOT punch marks. 3. Remove inboard joint tulip. 4. Remove snap ring, tripod and inboard joint boot. 5. Remove dynamic damper and outboard joint boot. DO NOT disassemble outboard joint. 6. Remove dust cover from inboard joint tulip and outboard joint shaft. 7. Mount outboard shaft in soft-jaw vise. Using a hammer and screwdriver, remove No. 2 dust cover. Use caution not to damage ABS sensor on outboard joint shaft. See Fig. 1 .
Reassembly

NOTE:

Prior to assembly of axle shaft, wrap vinyl tape on splines to prevent damage to boots.

1. 2. 3. 4. 5. 6. 7. 8.

9. 10.

Install NEW No. 2 dust deflector. Install dust cover for inboard joint tulip and outboard joint shaft. See Fig. 1 . Temporarily install boots, dynamic damper on right axle shaft and NEW clamps. Place beveled side of tripod axial spline toward outboard joint boot and align reference marks placed before removal. Using brass drift and hammer, tap in tripod. Install snap ring. Install boots to outboard and inboard joints. Pack grease to outboard and inboard joints and inside boots. See BOOT GREASE SPECIFICATIONS for grease capacities. Ensure boots are properly installed on shaft grooves. Ensure boots are not stretched or collapsed when axle shaft is at standard length. See AXLE SHAFT LENGTH SPECIFICATIONS . See Fig. 2 . Install inboard joint boot clamps and small outboard joint boot clamp with pliers. Using clamping tool, tighten large outboard joint boot clamp so that the clamp is pinched. Use wire gauge to measure the clearance of the clamp. The measured value should be less than .075 in. (1.9 mm). See Fig. 3 . Locate damper on right axle shaft, and position damper on axle shaft so damper installation distance on axle shaft is 16.862-17.098 in. (428.3-434.3 mm). See Fig. 4 . Using clamping tool, tighten damper clamp so that the clamp is pinched. Use wire gauge to measure the clearance of the clamp. The specified value should be less than .075 in. (1.9 mm).

Installation

Install snap ring to inboard joint shaft. Set snap ring with opening side facing down. Coat gear oil to inboard joint shaft and differential case sliding surface. Using brass drift and hammer, install axle shaft. Use caution to not damage dust cover and oil seal. Ensure there is .08-.12 in. (2.0-3.0 mm) play in shaft in axial direction, and that shaft cannot be pulled out by hand. 5. Connect lower control arm to lower ball joint. Tighten bolt and nuts to specification. See TORQUE SPECIFICATIONS . 6. Connect tie rod end to steering knuckle. Tighten nut to specification.

1. 2. 3. 4.

2002 AXLE SHAFTS FWD Axle Shafts - Corolla

7. 8. 9. 10. 11. 12.

Install hub nut. Tighten to specification. Fill with appropriate transaxle fluid and check for correct fluid level. Install lower engine cover. Install front wheels. Check wheel alignment. See appropriate WHEEL ALIGNMENT article. Check ABS speed sensor signal, if equipped.

2002 AXLE SHAFTS FWD Axle Shafts - Corolla

Fig. 1: Exploded View Of Axle Shaft Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 AXLE SHAFTS FWD Axle Shafts - Corolla

Fig. 2: Measuring Axle Shaft Standard Length Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 3: Adjusting Clamp Clearances Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 AXLE SHAFTS FWD Axle Shafts - Corolla

Fig. 4: Measuring Axle Shaft Damper Location Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

BOOT GREASE SPECIFICATIONS

BOOT GREASE SPECIFICATIONS Application Outboard Inboard Oz. (g) 5.8-6.5 (165-185) 6.7-7.4 (190-210)

AXLE SHAFT LENGTH SPECIFICATIONS

AXLE SHAFT LENGTH SPECIFICATIONS Fig. 2 Application Left Side Right Side Length - In. (mm) 21.07-21.46 (535.2-545.2) 33.56-33.95 (852.4-862.4)

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS Application ABS Speed Sensor Bolt Axle Hub Nut Lower Control Arm-To-Steering Knuckle Bolts/Nuts Tie Rod Nuts Wheel Lug Nuts (1) Tighten bolt to 71 INCH Lbs. (8.0 N.m). Ft. Lbs. (N.m)
(1)

166 (225) 105 (142) 36 (49) 76 (103)

2002 STEERING Power Steering System - Corolla

2002 STEERING Power Steering System - Corolla

STEERING SYSTEM
PRECAUTION

Care must be taken to replace parts properly because they could affect the performance of the steering system and result in a driving hazard. The Corolla is equipped with an SRS (Supplemental Restraint System) such as the driver airbag and front passenger airbag. Failure to carry out service operation in the correct sequence could cause the SRS to unexpectedly deploy during servicing, possibly leading to a serious accident. Before servicing (including removal or installation of parts, inspection or replacement), be sure to read the precautionary notices in the RS section.

TROUBLESHOOTING
PROBLEM SYMPTOMS TABLE Use the table below to help you find the cause of the problem. The numbers indicate the priority of the likely cause of the problem. Check each part in the order shown. If necessary, repair or replace these parts.

2002 STEERING Power Steering System - Corolla

Fig. 1: Troubleshooting Problem Symptoms Table Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

DRIVE BELT
INSPECTION

2002 STEERING Power Steering System - Corolla

Inspect Drive Belt

NOTE:

Cracks on the rib side of a belt are considered acceptable. If the missing chunks from the ribs are found on the drive belt, it should be replaced.

Fig. 2: Identifying Belt Defects Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

After installing a drive belt, check that it fits properly in the ribbed grooves.

Fig. 3: Inspecting Belt Installation

2002 STEERING Power Steering System - Corolla

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Check with your hand to confirm that the drive belt has not slipped out of the groove on the bottom of the pulley.

Visually check the drive belt for excessive wear, frayed cords, etc. If any defect has been found, replace the drive belt.

POWER STEERING FLUID

BLEEDING 1. Check fluid level. See INSPECTION . 2. Jack up front of vehicle and support it with stands . 3. Turn steering wheel . With the engine stopped, turn the steering wheel slowly from lock to lock several times. 4. Lower vehicle . 5. start Engine . Run the engine at idle for a few minutes. 6. Turn steering wheel : a. With the engine idling, turn the steering wheel to left or right full lock position and keep it there for 2 - 3 seconds, then turn the steering wheel to the opposite full lock position and keep it there for 2 - 3 seconds. b. Repeat ( ) several times. 7. Stop engine . 8. Check for foaming or emulsification . If the system has to be bled twice specifically because of foaming or emulsification, check for fluid leaks in the system. 9. Check fluid level . See INSPECTION .

2002 STEERING Power Steering System - Corolla

Fig. 4: Inspecting Brake Fluid For Air Bubbles Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSPECTION 1. Check fluid level : a. Keep the vehicle level. NOTE: HINT: Check that the fluid level is within the HOT level range on the reservoir. If the fluid is cold, check that it is within the COLD level range.

b. With the engine stopped, check the fluid level in the oil reservoir. If necessary, add fluid. Fluid: ATF DEXRON(R)II or III . c. Start the engine and run it at idle. d. Turn the steering wheel from lock to lock several times to boost fluid temperature. Fluid temperature: 80C (176F) .

2002 STEERING Power Steering System - Corolla

Fig. 5: Identifying Brake Fluid Reservoir Fluid Level Marks Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. e. Check for foaming or emulsification. If there is foaming or emulsification, bleed power steering system. See REPLACEMENT .

2002 STEERING Power Steering System - Corolla

Fig. 6: Inspecting Brake Fluid For Air Bubbles Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. f. With the engine idling, measure the fluid level in the oil reservoir. g. Stop the engine. h. Wait a few minutes and remeasure the fluid level in the oil reservoir. Maximum fluid level rise: 5 mm (0.20 in.) If a problem is found, bleed power steering system. See REPLACEMENT . i. Check the fluid level.

2002 STEERING Power Steering System - Corolla

Fig. 7: Measuring Brake Fluid Level Fluctuation Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 2. Check steering fluid pressure : a. Disconnect the pressure feed tube from the PS gear. See REMOVAL . NOTE: Check that the valve of the SST is in the open position.

2002 STEERING Power Steering System - Corolla

Fig. 8: Installing Brake Fluid Pressure Gauge Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Connect SST, as shown in the illustration below. SST 09640-10010 (09641-01010, 0964101020, 09641-01030). c. Bleed the power steering system. See REPLACEMENT . d. Start the engine and run it at idle. e. Turn the steering wheel from lock to lock several times to boost fluid temperature. Fluid temperature: 80C (176F) . NOTE:

Do not keep the valve closed for more than 10 seconds. Do not let the fluid temperature become too high.

2002 STEERING Power Steering System - Corolla

Fig. 9: Diagramming Brake Fluid Pressure Test With Valve Closed Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. f. With the engine idling, close the valve of the SST and observe the reading on the SST. Minimum fluid pressure: 6,374 kPa (65 kgf/cm2 , 925 psi) . g. With the engine idling, open the valve fully. NOTE: Do not turn the steering wheel.

2002 STEERING Power Steering System - Corolla

Fig. 10: Diagraming Brake Fluid Pressure Test With Valve Open Wheels Centered Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. h. Measure the fluid pressure at engine speeds of 1,000 rpm and 3,000 rpm. Difference fluid pressure: 490 kPa (5 kgf/cm2 , 71 psi) or less . NOTE:

Do not maintain lock position for more than 10 seconds. Do not let the fluid temperature become too high.

i. With the engine idling and valve fully opened, turn the steering wheel to full lock. Minimum fluid pressure: 6,374 kPa (65 kgf/cm2 , 925 psi) . j. Disconnect the SST. SST 09640-10010 (09641-01010, 09641-01020, 09641-01030). k. Connect the pressure feed tube to the PS gear. See INSTALLATION . l. Bleed the power steering system. See REPLACEMENT .

2002 STEERING Power Steering System - Corolla

Fig. 11: Diagraming Brake Fluid Pressure Test With Valve Open Wheels At Full Lock Position Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

STEERING WHEEL
INSPECTION 1. Check steering wheel freeplay : a. Stop the vehicle and face the tires straight ahead. b. Rock the steering wheel gently up and down with a finger lightly, check the steering wheel freeplay. Maximum freeplay: 30 mm (1. 18 in.) .

2002 STEERING Power Steering System - Corolla

Fig. 12: Inspecting Steering Wheel Free Play Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 2. Check steering effort : a. Center the steering wheel. b. Remove the steering wheel pad. See step 1 under REMOVAL. c. Start the engine and run it at idle. NOTE: Take the tire type, pressure and contact surface into consideration before making your diagnosis.

d. Measure the steering effort in both directions. Steering effort (Reference): 4.9 N.m (50 kgf.cm, 43 in..lbf) . e. Install the steering wheel set nut. Torque: 34 N.m (350 kgf.cm, 25 ft.lbf) .

2002 STEERING Power Steering System - Corolla

Fig. 13: Installing Steering Wheel Set Nut Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. f. Install the steering wheel pad. See 14 in installation under STEERING COLUMN.

STEERING COLUMN
COMPONENTS

2002 STEERING Power Steering System - Corolla

ACC, DTCs will be recorded. 1. Remove steering wheel pad : a. Place the front wheels facing straight ahead. b. Remove the 2 steering wheel lower No. 2 covers. c. Using a torx socket wrench, loosen the 2 torx screws until the groove along the screw circumference catches on the screw case.

Fig. 18: Locating Steering Pad Torx Screws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. WARNING:

When storing the wheel pad, keep the upper surface of the pad facing upward. Never disassemble the wheel pad. When removing the wheel pad, take care not to pull the airbag wire harness.

2002 STEERING Power Steering System - Corolla

Fig. 19: Locating Air Bag Connector & Identifying Safe Air Bag Handling Procedures Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 STEERING Power Steering System - Corolla

d. Pull out the wheel pad from the steering wheel and disconnect the airbag connector. 2. Remove steering wheel : a. Disconnect the connector. b. Remove the steering wheel set nut. c. Place matchmarks on the steering wheel and main shaft assembly.

Fig. 20: Matchmarking Steering Wheel & Main Shaft Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. d. Using SST, remove the steering wheel. SST 09950-50013 (09951-05010, 09952-05010, 0995305020, 09954-05021). 3. Remove front door scuff plate and cowl side trim . 4. Remove lower LH instrument finish panel : a. Disconnect the hood lock control cable. b. Remove the 2 bolts and lower LH instrument finish panel. 5. Remove the 2 bolts and lower LH instrument panel insert. 6. Remove column upper and lower covers : a. Remove the 3 screws and column lower cover. b. Remove the screw and column upper cover. 7. Remove combination switch with spiral cable : a. Disconnect the 3 connectors. b. Disconnect the airbag connector.

2002 STEERING Power Steering System - Corolla

c. Remove the 3 screws and combination switch with spiral cable. NOTE: 8. 9. 10. 11. Do not disassemble the cable or apply oil to it.

Remove spiral cable . Remove the clip and No. 2 heater to register duct . Remove the 5 bolts and column hole cover . Disconnect sliding yoke : a. Place matchmarks on the sliding yoke and control valve shaft.

2002 STEERING Power Steering System - Corolla

Fig. 21: Matchmarking Sliding Yoke & Control Valve Shaft Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Loosen the bolt A and remove the bolt B. 12. Remove steering column assembly : a. Disconnect the connectors.

2002 STEERING Power Steering System - Corolla

b. Remove the 2 column assembly set bolts, nuts and steering column assembly. 13. Remove the bolt A and sliding yoke . DISASSEMBLY NOTE: When using a vise, do not overtighten it.

1. w/ Key cylinder lamp : Remove the clip and key cylinder lamp assembly. 2. Remove column upper bracket and column upper clamp : a. Using a centering punch, mark the center of the 2 tapered-head bolts. b. Using a 3 - 4 mm (0.12 - 0.16 in.) drill, drill into the 2 bolts. c. Using a screw extractor, remove the 2 bolts, column upper bracket and column upper clamp.

Fig. 22: Removing Tapered-Head Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSPECTION 1. Inspect steering lock operation : Check that the steering lock mechanism operates properly.

2002 STEERING Power Steering System - Corolla

Fig. 23: Inspecting Steering Lock Operation Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 2. If necessary, replace key cylinder : a. Place the ignition key at the ACC position. b. Push down the stop pin with a screwdriver, and pull out the cylinder. c. Install a new key cylinder. HINT: Make sure the key is at the ACC position. 3. Inspect ignition switch . 4. Inspect key unlock warning switch . 5. If necessary, replace ignition switch with key unlock warning switch : a. Remove the 2 screws and slide the ignition switch with key unlock warning switch out of the column upper bracket. b. Slide a new ignition switch with key unlock warning switch in the column upper bracket and install the 2 screws. 6. A/T: inspect : KEY INTERLOCK SOLENOID 7. A/T: if necessary, replace key interlock solenoid : a. Remove the 2 screws and key interlock solenoid.

2002 STEERING Power Steering System - Corolla

b. Install a new key interlock solenoid with the 2 screws.

Fig. 24: Replacing Key Interlock Solenoid Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REASSEMBLY NOTE: When using a vise, do not overtighten it.

1. Install column upper bracket and column upper clamp : a. Install the column upper bracket and column upper clamp with the 2 new tapered-head bolts. b. Tighten the new tapered-head bolts until the bolt heads break off. 2. W/key cylinder lamp: Install the key cylinder lamp assembly with the clip.

2002 STEERING Power Steering System - Corolla

Fig. 25: Locating Tapered-Head Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSTALLATION 1. Temporarily install the sliding yoke and bolt A . 2. Install steering column assembly : a. Install the steering column assembly with the 2 set bolts and nuts. Torque: 26 N.m (260 kgf.cm, 19 ft.lbf) b. Connect the connectors. 3. Connect sliding yoke : a. Align the matchmarks on the sliding yoke and control valve shaft.

2002 STEERING Power Steering System - Corolla

Fig. 26: Locating Sliding Yoke & Control Valve Shaft Matchmarks Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Install the bolt B. Torque: 35 N.m (360 kgf.cm, 26 ft.lbf) . c. Torque the bolt A. Torque: 35 N.m (360 kgf.cm, 26 ft.lbf) . 4. Install the column hole cover with the 5 bolts . Torque: 4.9 N.m (50 kgf.cm, 43 in..lbf)

2002 STEERING Power Steering System - Corolla

5. Install the No. 2 heater to register duct with the clip . 6. Install spiral cable . 7. Install combination switch with spiral cable : a. Install the combination switch with spiral cable with the 3 screws. b. Connect the airbag connector. c. Connect the 3 connectors. 8. Install column upper and lower covers a. Install the column upper cover with the screw. b. Install the column lower cover with the 3 screws. 9. Install the lower LH instrument panel insert with the 2 bolts . 10. Install lower LH instrument finish panel : a. Connect the hood lock control cable. b. Install the lower LH instrument finish panel with the 2 bolts. 11. Install front door scuff plate and cowl side trim . 12. Center spiral cable : a. Check that the front wheels are facing straight ahead. b. Turn the spiral cable counterclockwise by hand until it becomes harder to turn. NOTE: The cable will rotate about 2.5 turns to either left or right of the center.

2002 STEERING Power Steering System - Corolla

Fig. 27: Locating Spiral Cable Matchmarks Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Then rotate the spiral cable clockwise about 2.5 turns to align the marks. 13. Install steering wheel : a. Align the matchmarks on the steering wheel and main shaft assembly. b. Install the steering wheel set nut. Torque: 50 N.m (510 kgf.cm, 37 ft.lbf) . c. Connect the connector. NOTE:

Never use airbag parts from another vehicle. When replacing parts, replace with new ones. Make sure the wheel pad is installed with the specified torque. If the wheel pad has been dropped, or if there are cracks, dents or other defects in the case or connector, replace the wheel pad with a new one. When installing the wheel pad, take care that the wirings do not interfere with other parts and that they are not pinched between other parts.

14. Install steering wheel pad : a. Connect the airbag connector.

2002 STEERING Power Steering System - Corolla

b. Install the wheel pad after confirming that the circumference groove of the torx screws is caught on the screw case. c. Using a torx socket wrench, install the 2 screws. Torque: 8.8 N.m (90 kgf.cm, 78 in..lbf) . d. Install the 2 steering wheel lower No. 2 covers. 15. Check steering wheel center point .

Fig. 28: Locating Steering Pad Torx Screws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

POWER STEERING VANE PUMP

COMPONENTS

2002 STEERING Power Steering System - Corolla

2. Loosen the drive belt tension by turning the drive belt tensioner arm clockwise, and remove the drive belt. NOTE: Take care not to spill fluid on the drive belt.

Fig. 31: Removing Serpentine Belt Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 3. Remove the clip and disconnect the suction hose. 4. Remove oil pressure switch : a. Disconnect the connector. CAUTION: Be careful not to drop the pressure switch.

b. Remove the oil pressure switch, as shown in the illustration. If the oil pressure switch is dropped or strongly damaged, replace it with a new one. 5. Remove the union bolt and gasket, and disconnect the pressure feed tube.

2002 STEERING Power Steering System - Corolla

Fig. 32: Removing Pressure Feed Tube Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 6. Remove vane pump pulley : a. Using SST, stop the pulley rotating and loosen the nut. b. Remove the nut and vane pump pulley from the vane pump shaft. SST 09960-10010 (0996201000, 09963-01000). 7. Remove the 2 pump assembly set bolts, nuts and the PS vane pump assembly.

2002 STEERING Power Steering System - Corolla

Fig. 33: Removing Vane Pump Pulley Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. DISASSEMBLY NOTE: When using a vise, do not overtighten it.

1. Measure PS vane pump rotating torque : a. Check that the vane pump rotates smoothly without abnormal noise. b. Temporarily install the vane pump pulley set nut. c. Using a torque wrench, check the vane pump rotating torque. Rotating torque: 0.3 N.m (2.8 kgf.cm, 2.4 in..lbf) or less . 2. Remove suction port union : a. Remove the bolt from the bracket of the suction port union. b. Remove the 2 suction port union set bolts and suction port union. c. Remove the O-ring from the suction port union. 3. Remove the union bolt, 2 gaskets and pressure feed No. 1 tube. 4. Remove pressure port union : a. Remove the pressure port union. b. Remove the O-ring from the pressure port union. 5. Remove flow control valve and spring .

2002 STEERING Power Steering System - Corolla

6. Remove rear housing, wave washer and side plate : a. Remove the 4 bolts and rear housing. b. Remove the O-ring from the rear housing. c. Remove the wave washer and side plate. d. Remove the O-ring from the side plate. CAUTION: Be careful not to drop the plate.

Fig. 34: Disassembling Vane Pump Components Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 7. 8. 9. 10. Remove cam ring, 10 vane plates and vane pump rotor . Remove gasket . Using pliers, remove the 2 straight pins from the front housing. Remove vane pump shaft with bearing : a. Using snap ring pliers, remove the snap ring from the front housing. b. Wind vinyl tape on the serrated part of the vane pump shaft. c. Press out the vane pump shaft with the bearing.

2002 STEERING Power Steering System - Corolla

NOTE:

Be careful not to damage the oil seal lip.

Fig. 35: Locating & Identifying Vane Pump Shaft Components Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSPECTION NOTE: When using a vise, do not overtighten it.

1. Using a micrometer and caliper gauge, measure the oil clearance between vane pump shaft and bushing: Standard clearance: 0.03 - 0.05 mm (0.0012 - 0.0020 in.) . Maximum clearance: 0.07 mm (0.0028 in.) .

2002 STEERING Power Steering System - Corolla

Fig. 36: Measuring Vane Pump Shaft To Bushing Oil Clearance Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. If it is more than the maximum, replace the front housing and vane pump shaft. 2. Inspect vane pump rotor and vane plates : a. Using a micrometer, measure the height, thickness and length of the 10 vane plates. Minimum height: 8.6 mm (0.339 in.) . Minimum thickness: 1.397 mm (0.05500 in.) . Minimum length: 14.991 mm (0.59016 in.) .

2002 STEERING Power Steering System - Corolla

Fig. 37: Measuring Vane Plates Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE: HINT: There are 5 vane plate lengths corresponding to the following vane pump rotor and cam ring marks: Inscribed mark: 1, 2, 3, 4 or None .

2002 STEERING Power Steering System - Corolla

Fig. 38: Locating Rotor & Cam Ring marks Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 STEERING Power Steering System - Corolla

Fig. 39: Measuring Rotor Groove & Plate Clearance Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 STEERING Power Steering System - Corolla

Fig. 40: Rotor & Cam Ring Identification/Specifications Chart Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Using a feeler gauge, measure the clearance between the vane pump rotor groove and vane plate. Maximum clearance: 0.03 mm (0.0012 in.) . If it is more than the maximum, replace the vane plate and/or vane pump rotor with the one having the same mark stamped on the cam ring. 3. Inspect flow control valve : a. Coat the valve with power steering fluid and check that it falls smoothly into the valve hole by its own weight.

2002 STEERING Power Steering System - Corolla

Fig. 41: Inspecting Flow Control Valve Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE: Install a new flow control valve with the same inscribed mark as the old one. Inscribed mark: A, B, C, D, E or F .

2002 STEERING Power Steering System - Corolla

Fig. 42: Locating Flow Control Valve Marks Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

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Fig. 43: Testing Flow Control Valve Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Check the flow control valve for leakage. Close one of the holes and apply compressed air of 392 - 490 kPa (4 - 5 kgf/cm2 , 57 - 71 psi) into the opposite side hole, and confirm that air does not come out from the end hole. If necessary, replace the flow control valve. 4. Inspect spring : Using vernier calipers, measure the free length of the spring. Minimum free length: 33.2 mm (1.307 in.) . If it is less than the minimum, replace the spring.

2002 STEERING Power Steering System - Corolla

Fig. 44: Measuring Flow Control Valve Spring Length Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REPLACEMENT NOTE: When using a vise, do not overtighten it.

1. If necessary, replace oil seal : CAUTION: Be careful not to damage the bushing of the front housing.

2002 STEERING Power Steering System - Corolla

Fig. 45: Removing Oil Seal Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. a. Using SST, tap out the oil seal from the front housing. SST 09631-10030. b. Coat a new oil seal lip with power steering fluid. NOTE: Make sure to install the oil seal facing in the correct direction.

2002 STEERING Power Steering System - Corolla

Fig. 46: Installing Oil Seal Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Using SST, press in the oil seal. SST 09950-60010 (09951-00340), 09950-70010 (0995107100). 2. If necessary, replace bearing : a. Press out the bearing from the vane pump shaft. CAUTION: Be careful not to damage the vane pump shaft.

b. Using snap ring expander, replace the snap ring with new one. c. Coat a new bearing with power steering fluid. d. Press in the bearing to the vane pump shaft.

2002 STEERING Power Steering System - Corolla

Fig. 47: Removing & Installing Vane Pump Shaft Bearing Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REASSEMBLY NOTE: When using a vise, do not overtighten it.

1. Coat parts indicated by arrows with power steering fluid . See COMPONENTS under POWER STEERING VANE PUMP. 2. Install vane pump shaft with bearing : a. Wind vinyl tape on the serrated part of the vane pump shaft. CAUTION: Be careful not to damage the oil seal.

b. Using SST, press in the vane pump shaft with the bearing. SST 09608-04031. c. Using snap ring pliers, install a new snap ring to the front housing. CAUTION: Be careful not to damage the pins.

2002 STEERING Power Steering System - Corolla

Fig. 48: Locating & Identifying Vane Pump Shaft Components Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 3. Using a plastic hammer, tap in 2 new straight pins to the front housing. NOTE: Align the holes of the cam ring with the 2 straight pins.

4. Install the cam ring with the inscribed mark facing outward. 5. Install the vane pump rotor with the inscribed mark facing outward.

2002 STEERING Power Steering System - Corolla

Fig. 49: Installing Vane Pump Rotor Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 6. Install 10 vane plates and gasket : a. Install the 10 vane plates with the round end facing outward. CAUTION: Be careful of the direction of the gasket.

2002 STEERING Power Steering System - Corolla

Fig. 50: Installing Vane Plates Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Install a new gasket on the front housing. 7. Install side plate : a. Coat a new O-ring with power steering fluid and install it to the side plate. b. Align the holes of the side plate and 2 straight pins, and install the side plate. 8. Install the wave washer so that its protrusions fit into the slots in the side plate.

2002 STEERING Power Steering System - Corolla

Fig. 51: Installing Wave Washer Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 9. Install rear housing : a. Coat a new O-ring with power steering fluid and install it to the rear housing. b. Install the rear housing with the 4 bolts. Torque: 24 N.m (240 kgf.cm, 17 ft.lbf) . 10. Install spring and flow control valve : a. Install the spring. b. Install the flow control valve facing in the correct direction. See COMPONENTS under POWER STEERING VANE PUMP. 11. Install pressure port union : a. Coat a new O-ring with power steering fluid and install it to the pressure port union. b. Install the pressure port union. Torque: 83 N.m (850 kgf.cm, 61 ft.lbf) . 12. Install new gasket on each side of the pressure feed No. 1 tube. Install the pressure feed No. 1 tube with the union bolt.Torque: 69 N.m (700 kgf.cm, 51 ft.lbf) . 13. Install suction port union : a. Coat a new O-ring with power steering fluid and install it to the suction port union. b. Install the suction port union with the 2 union set bolts. Torque: 13 N.m (130 kgf.cm, 10 ft.lbf) . c. Install the bolt to the bracket of the suction port union. Torque: 43 N.m (440 kgf.cm, 32 ft.lbf) .

2002 STEERING Power Steering System - Corolla

14. Measure PS vane pump rotating torque. See step 1 in DISASSEMBLY under POWER STEERING VANE PUMP. INSTALLATION 1. Install the PS vane pump assembly with the 2 pump assembly set bolts and nuts . Torque: 37 N.m (370 kgf.cm, 27 ft.lbf) 2. Install vane pump pulley : a. Install the vane pump pulley and nut to the vane pump shaft.

Fig. 52: Installing PS Vane Pump Pulley Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Using SST, stop the vane pump pulley rotating and torque the nut. Torque: 43 N.m (440 kgf.cm, 32 ft.lbf) . SST 09960-10010 (09962-01000, 09963-01000). NOTE: Make sure that the stopper of the pressure feed tube touches the pressure feed No. 2 tube as shown in the illustration, then torque the union bolt.

2002 STEERING Power Steering System - Corolla

Fig. 53: Locating pressure feed tube, stopper & union bolt Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 3. Install a new gasket, and connect the pressure feed tube with the union bolt . Torque: 54 N.m (550 kgf.cm, 40 ft.lbf) . CAUTION: Be careful of oil on the connector.

4. Install the oil pressure switch . Torque: 21 N.m (210 kgf.cm, 15 ft.lbf) Connect the connector. 5. Connect the suction hose with the clip . 6. Loosen the drive belt tension by turning the drive belt tensioner arm clockwise, and install the drive belt .

2002 STEERING Power Steering System - Corolla

Fig. 54: Installing Serpentine Belt Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 7. Install the RH engine under cover with the 4 bolts and 2 screws . 8. Bleed power steering system . See REPLACEMENT .

POWER STEERING GEAR

COMPONENTS

2002 STEERING Power Steering System - Corolla

Fig. 58: Indentifying Power Steering Gear Components (4 Of 4) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL NOTE: Remove the steering wheel assembly before the steering gear removal, because there is possibility of breaking of the spiral cable.

1. 2. 3. 4. 5. 6.

Place front wheels facing straight ahead . Remove steering wheel pad . See step 1 under REMOVAL. Remove steering wheel . See 2 under REMOVAL. Remove the 8 bolts, 4 screws and RH and LH engine under covers. Disconnect RH and LH tie rod ends. See FRONT AXLE HUB & WHEEL BEARING . Remove column hole cover Remove the 5 bolts and column hole cover.

7. 8. 9. 10.

Disconnect sliding yoke . See 11 in REMOVAL under STEERING COLUMN. Disconnect lower ball joint from lower suspension arm . Remove the 2 nuts and brace. Remove front sub-frame and lower suspension arm : a. Using an engine support fixture, support the engine.

2002 STEERING Power Steering System - Corolla

b. Remove the 14 bolts, 3 nuts and front sub-frame and lower suspension arm.

Fig. 59: Locating Mounting Bolts & Nuts Sub-Frame/Lower Suspension Arm Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 11. Remove the bolt and engine rear mount insulator from the engine rear mount bracket. 12. Remove engine rear mount bracket . A131L A/T: Remove the 2 bolts, drive shaft heat insulator set nut and engine rear mount bracket.

M/T, A245E A/T: Remove the 3 bolts, drive shaft heat insulator set nut and engine rear mount bracket.

13. Remove Rack Boot Heat Insulator Remove the bolt, nut and rack boot heat insulator. 14. Disconnect 2 Tube Clamps

2002 STEERING Power Steering System - Corolla

Remove the 2 bolts and 2 tube clamps. 15. Disconnect Return Hose Remove the clip and disconnect the return hose. 16. Using SST, disconnect the pressure feed tube . SST 09023-12700.

Fig. 60: Disconnecting Pressure Feed Tube Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 17. Remove 2 grommets and brackets : a. Remove the bolt A.

2002 STEERING Power Steering System - Corolla

Fig. 61: Locating Bolt "A" Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the bolt, nut, bracket and grommet. c. Employ the same manner described above to the other side. 18. Remove PS gear assembly : a. Slide the PS gear assembly to the RH side of the vehicle.

2002 STEERING Power Steering System - Corolla

Fig. 62: Removing PS Gear Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE: Do not damage the turn pressure tubes.

b. Slide the PS gear assembly to the LH side and pull it out. DISASSEMBLY NOTE: When using a vise, do not overtighten it.

1. SECURE PS GEAR ASSEMBLY IN VISE Using SST, secure the PS gear assembly in a vise. SST 09612-00012.

2002 STEERING Power Steering System - Corolla

Fig. 63: Securing PS Gear In Vise Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 2. Remove 2 turn pressure tubes : a. Using SST, remove the 2 turn pressure tubes. SST 09023-38200.

2002 STEERING Power Steering System - Corolla

Fig. 64: Identifying Pressure Tube Union Nuts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the 4 O-rings from the 2 turn pressure tubes. 3. Remove RH and LH tie rod ends and lock nuts : a. Place matchmarks on the tie rod end and rack end.

2002 STEERING Power Steering System - Corolla

Fig. 65: Matchmarking Tie Rod & Rack End Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Loosen the lock nut, and remove the tie rod end and lock nut. c. Employ the same manner described above to the other side. 4. Remove RH And LH Clips, Rack Boots And Clamps CAUTION: Be careful not to damage the boot.

2002 STEERING Power Steering System - Corolla

Fig. 66: Removing Clamps Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. a. Using pliers, loosen the clamp. NOTE: Mark the RH and LH rack boots.

b. Remove the clip and boot. c. Employ the same manner described above to the other side. 5. Remove RH And LH Rack Ends And Claw Washers CAUTION: Avoid any impact on the steering rack.

2002 STEERING Power Steering System - Corolla

Fig. 67: Unstaking Washer Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. a. Using a chisel and hammer, unstake the washer. NOTE:

Use SST 09922-10010 in the direction shown in the illustration. Mark the RH and LH rack ends.

2002 STEERING Power Steering System - Corolla

Fig. 68: Remove Rack End & Claw Washer Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Using SST, remove the rack end and claw washer. SST 09922-10010. c. Employ the same manner described above to the other side. NOTE: Use SST 09922-10010 in the direction shown in the illustration.

2002 STEERING Power Steering System - Corolla

Fig. 69: Removing Rack Guide Spring Cap Lock Nut Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 6. Using SST, remove the rack guide spring cap lock nut . SST 09922-10010. 7. Remove rack guide spring cap, rack guide spring, conical spring washer, rack guide subassembly : a. Using a hexagon wrench (19 mm), remove the rack guide spring cap. b. Remove the rack guide spring, conical spring washer, rack guide subassembly. 8. Remove rack housing cap .

2002 STEERING Power Steering System - Corolla

Fig. 70: Removing Control Valve Shaft Self-Locking Nut Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 9. Using SST, stop the control valve shaft rotating and remove the self-locking nut . SST 0961600011. 10. Remove control valve housing with control valve assembly : a. Place matchmarks on the control valve housing and rack housing.

2002 STEERING Power Steering System - Corolla

Fig. 71: Matchmarking Control Valve & Rack Housing Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the 2 bolts and control valve housing with the control valve assembly. c. Remove the gasket from the control valve housing. 11. Remove control valve assembly and oil seal : a. To prevent oil seal lip damage, wind vinyl tape on the serrated part of the control valve shaft. CAUTION: Be careful not to damage the oil seal lip.

2002 STEERING Power Steering System - Corolla

Fig. 72: Removing Control Valve Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Using a plastic hammer, tap out the control valve assembly with the oil seal from the control valve housing. c. Remove the oil seal from the control valve assembly.

2002 STEERING Power Steering System - Corolla

Fig. 73: Removing Oil Seal From Control Valve Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 12. Remove cylinder end stopper : a. Using SST, turn the cylinder end stopper clockwise until the wire end is visible through the service hole. SST 09631-10021 b. Using SST, turn the cylinder end stopper counterclockwise, and remove the wire. SST 0963110021. 13. Remove steering rack with bushing : CAUTION: Take care not to drop the steering rack.

2002 STEERING Power Steering System - Corolla

Fig. 74: Remove Steering Rack Bushing Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. a. Using SST, press out the steering rack with the bushing. SST 09612-24014 (09612-10061). b. Remove the O-ring from the bushing. CAUTION: Do not damage the rack housing.

2002 STEERING Power Steering System - Corolla

Fig. 75: Remove Steering Rack Oil Seal Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 14. Using SST, press out the oil seal . SST 09950-60010 (09951-00260), 09950-70010 (09951-07360). INSPECTION NOTE: When using a vise, do not overtighten it.

INSPECT STEERING RACK

a. Using a dial indicator, check the steering rack for runout and for teeth wear and damage. Maximum runout: 0.30 mm (0.0118 in.)

2002 STEERING Power Steering System - Corolla

Fig. 76: Measuring Steering Rack Runout Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Check the back surface for wear and damage. REPLACEMENT NOTE: When using a vise, do not overtighten it.

1. If necessary, replace oil seal and bearing : a. Using SST, press out the oil seal and bearing from the control valve housing. SST 09950-60010 (09951-00260), 09950-70010 (09951-07100).

2002 STEERING Power Steering System - Corolla

Fig. 77: Identifying Control Valve Housing Oil Seal & Main Bearing Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Coat a new oil seal lip with power steering fluid. NOTE: Make sure to install the oil seal facing in the correct direction.

2002 STEERING Power Steering System - Corolla

Fig. 78: Installing Control Valve Housing Oil Seal Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Using SST, press in the oil seal. SST 09950-60010 (09951-00180, 09951-00320, 09952-06010), 09950-70010 (09951-07100). d. Coat a new bearing with molybdenum disulfide lithium base grease. e. Using SST, press in the bearing. SST 09950-60010 (09951-00190, 09951-00360, 0995206010), 09950-70010 (09951-07100).

2002 STEERING Power Steering System - Corolla

Fig. 79: Installing Control Valve Housing Main Bearing Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 2. If necessary, replace 2 bearings : a. Using SST, press out the bearing from the steering rack housing. SST 09950-70010 (0995107100).

2002 STEERING Power Steering System - Corolla

Fig. 80: Removing Control Valve Housing Side Bearing (1 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Using SST, press out the bearing from the steering rack housing. SST 09950-70010 (0995107100).

2002 STEERING Power Steering System - Corolla

Fig. 81: Removing Control Valve Housing Side Bearing (2 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Coat a new bearing with molybdenum disulfide lithium base grease. d. Using SST, press in the bearing. SST 09950-60010 (09951-00220, 09951-00280, 0995206010), 09950-70010 (09951-07100).

2002 STEERING Power Steering System - Corolla

Fig. 82: Installing Control Valve Housing Side Bearing (1 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. e. Coat a new bearing with molybdenum disulfide lithium base grease. f. Using SST, press in the bearing. SST 09950-60010 (09951-00280), 09950-70010 (0995107100).

2002 STEERING Power Steering System - Corolla

Fig. 83: Installing Control Valve Housing Side Bearing (2 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 3. If necessary, replace oil seal : CAUTION: Be careful not to damage the bushing.

NOTE:

As shown in the illustration, from the opposite side of SST confirm that its claws are firmly caught on the oil seal.

2002 STEERING Power Steering System - Corolla

Fig. 84: Removing Oil Seal From Bushing Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. a. Using SST, remove the oil seal from the bushing. SST 09612-24014 (09613-22011). b. Coat a new oil seal lip with power steering fluid. CAUTION: Make sure to install the oil seal facing in the correct direction.

2002 STEERING Power Steering System - Corolla

Fig. 85: Installing Oil Seal To Bushing Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Using SST, press in the oil seal. SST 09950-60010 (09951-00230, 09951-00370, 09952-06010), 09950-70010 (09951-07100). 4. If necessary, replace teflon ring : CAUTION: Be careful not to damage the groove for the teflon ring.

2002 STEERING Power Steering System - Corolla

Fig. 86: Removing "O" Ring From Teflon Ring Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. a. Using a screwdriver, remove the teflon ring from the steering rack. CAUTION: Be careful not to overexpand the teflon ring.

2002 STEERING Power Steering System - Corolla

Fig. 87: Preparing Teflon Ring For Installation Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Expand a new teflon ring with your fingers. c. Coat the teflon ring with power steering fluid.

2002 STEERING Power Steering System - Corolla

Fig. 88: Installing & Settling Teflon Ring Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. d. Install the teflon ring to the steering rack and settle it down with your fingers. CAUTION: Be careful not to damage the teflon ring.

2002 STEERING Power Steering System - Corolla

Fig. 89: Installing Teflon Ring On Steering Rack Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. e. Carefully slide the tapered end of SST over the teflon ring until it fits to the steering rack. SST 09630-24014 (09631-24031). 5. If necessary, replace 4 teflon rings : a. Using a screwdriver, remove the 4 teflon rings from the control valve assembly.

2002 STEERING Power Steering System - Corolla

Fig. 90: Removing Teflon Rings Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE: NOTE: b. c. d. e. Be careful not to damage the grooves for the teflon ring. Be careful not to overexpand the teflon ring.

Expand 4 new teflon rings with your fingers. Coat the teflon rings with power steering fluid. Install the teflon rings to the control valve assembly, and settle them down with your fingers. Carefully slide the tapered end of SST over the teflon rings until them fit to the control valve assembly. SST 09631-20081

2002 STEERING Power Steering System - Corolla

Fig. 91: Identifying SST 09631-20081 & Locating Teflon Rings Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE: REASSEMBLY NOTE: When using a vise, do not overtighten it. Be careful not to damage the teflon rings.

1. Coat parts indicated by arrows with power steering fluid or molybdenum disulfide lithium base grease . 2. Install oil seal : a. Coat a new oil seal lip with power steering fluid. CAUTION: Make sure to install the oil seal facing in the correct direction.

2002 STEERING Power Steering System - Corolla

Fig. 92: Pressing Oil Seal Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Using SST, press in the oil seal. SST 09950-60010 (09951-00240, 09951-00400, 09952-06010), 09950-70010 (09951-07360). Take care that the oil seal does not get reversed as you install it. 3. Install Steering Rack NOTE: If necessary, scrape the burrs off the steering rack teeth end and burnish

2002 STEERING Power Steering System - Corolla

Fig. 93: inspecting steering rack teeth & Installing SST 09631-16020 Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. a. Install SST to the steering rack. SST 09631-16020 b. Coat SST with power steering fluid. c. Install the rack into the rack housing.

2002 STEERING Power Steering System - Corolla

d. Remove the SST. 4. Install Bushing a. Coat a new O-ring with power steering fluid and install it to the bushing. b. To prevent oil seal lip damage, wind vinyl tape on the steering rack end, and apply power steering fluid.

Fig. 94: Identifying Bushing Installation Direction Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. CAUTION:

Make sure to install the bushing facing in the correct direction. Be careful not to damage the oil seal lip.

2002 STEERING Power Steering System - Corolla

Fig. 95: Installing Bushing Into Rack Housing Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Install the bushing into the rack housing. 5. Install cylinder end stopper : a. Align the installation hole for the wire of the cylinder end stopper with the slot of the rack housing. b. Install a new wire into the cylinder end stopper. c. Using SST, turn the cylinder end stopper clockwise 150 50. SST 09631-10021. 6. Air Tightness Test a. Install SST to the rack housing. SST 09631-12071.

2002 STEERING Power Steering System - Corolla

Fig. 96: Testing Air Tightness Of Rack Housing Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Apply 53 kPa (400 mmHg, 15.75 in.Hg) of vacuum for about 30 seconds. c. Check that there is no change in the vacuum. If there is change in the vacuum, check the installation of the oil seals. 7. Install control valve assembly : a. To prevent oil seal lip damage, wind vinyl tape on the serrated part of the control valve shaft.

2002 STEERING Power Steering System - Corolla

Fig. 97: Installing Control Valve Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Coat the teflon rings with power steering fluid. CAUTION: Be careful not to damage the teflon rings and oil seal.

c. Install the control valve assembly into the control valve housing. 8. Install Oil Seal a. Coat a new oil seal lip with power steering fluid. CAUTION: Make sure to install the oil seal facing in the correct direction.

2002 STEERING Power Steering System - Corolla

Fig. 98: Installing Control Valve Oil Seal Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Using SST, press in the oil seal. SST 09612-22011. 9. Install control valve housing with control valve assembly : a. Place a new gasket on the rack housing. b. Align the matchmarks on the control valve housing and rack housing.

2002 STEERING Power Steering System - Corolla

Fig. 99: Aligning Control Valve & Rack Housing Matchmarks Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Install the 2 bolts. Torque: 18 N.m (185 kgf.cm, 13 ft.lbf) . 10. Install Self-Locking Nut Using SST, stop the control valve shaft rotating and Install a new self-locking nut. Torque: 25 N.m (250 kgf.cm, 18 ft.lbf) . SST 09616-00011.

2002 STEERING Power Steering System - Corolla

Fig. 100: Installing Self-Locking Nut Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 11. Install Rack Housing Cap a. Apply sealant to 2 or 3 threads of the rack housing cap. Sealant : Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent. b. Install the rack housing cap. Torque: 59 N.m (600 kgf.cm, 43 ft.lbf) c. Using a punch and hammer, stake the 2 parts of the rack housing cap.

2002 STEERING Power Steering System - Corolla

Fig. 101: Staking Rack Housing Cap Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 12. Install Rack Guide Subassembly, Conical Spring Washer, Rack Guide Spring And Rack Guide Spring Cap a. Install the rack guide subassembly, conical spring washer and rack guide spring. b. Apply sealant to 2 or 3 threads of the rack guide spring cap. Sealant : Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent. c. Temporarily install the rack guide spring cap. 13. Adjust Total Preload a. To prevent the steering rack teeth from damaging the oil seal lip, temporarily install the RH and LH rack ends. b. Using a hexagon wrench (19 mm), install the rack guide spring cap.

2002 STEERING Power Steering System - Corolla

Fig. 102: Adjusting Preload (1 Of 3) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Torque: 25 N.m (250 kgf.cm, 18 ft.lbf) c. Using a hexagon wrench (19 mm), return the cap 12.

2002 STEERING Power Steering System - Corolla

Fig. 103: Adjusting Preload (1 Of 3) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. d. Using SST, turn the control valve shaft right and left 1 or 2 times. SST 09616-00011 e. Using a hexagon wrench (19 mm), loosen the rack guide spring cap until the rack guide spring is not functioning. f. Using SST, a torque wrench and hexagon wrench (19 mm), tighten the rack guide spring cap until the preload is within the specification. SST 09616-00011. Preload (turning): 0.8 - 1.4 N.m (8 - 14 kgf.cm, 6.9 - 12.2 in..lbf)

2002 STEERING Power Steering System - Corolla

Fig. 104: Adjusting Preload (1 Of 3) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 14. Install Rack Guide Spring Cap Lock Nut a. Apply sealant to 2 or 3 threads of the rack guide spring cap lock nut. Sealant: Part No. 08833-00080, Three Bond 1344, Loctite 242 or equivalent b. Temporarily install the lock nut. c. Using a hexagon wrench (19 mm), hold the rack guide spring cap and using SST, torque the nut.Torque: 43 N.m (439 kgf.cm, 32 ft.lbf) SST 09922-10010.

2002 STEERING Power Steering System - Corolla

Fig. 105: Installing Rack Guide Spring Cap Lock Nut Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE: Use SST 09922-10010 in the direction shown in the illustration.

HINT: Use a torque wrench with a fulcrum length of 345 mm (13.58 in.). d. Recheck the total preload. Preload (turning) : 0.8 - 1.4 N.m (8 - 14 kgf.cm, 6.9 - 12.2 in..lbf). e. Remove the RH and LH rack ends. 15. Install RH And LH claw washers and rack ends NOTE: Align the claws of the washer with the steering rack grooves.

2002 STEERING Power Steering System - Corolla

Fig. 106: Installing Claw Washers & Rack Ends Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. a. Install a new claw washer, and temporarily install the rack end. NOTE: Use SST 09922-10010 in the direction shown in the illustration. Use a torque wrench with a fulcrum length of 380 mm (14.96 in.).

2002 STEERING Power Steering System - Corolla

Fig. 107: Installing Rack End Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Using SST, torque the rack end. Torque: 62 N.m (633 kgf.cm, 46 ft.lbf) . SST 09922-10010. CAUTION: Avoid any impact on the steering rack.

2002 STEERING Power Steering System - Corolla

Fig. 108: Staking Claw Washer Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Using a brass bar and a hammer, stake the washer. d. Employ the same manner described above to the other side. 16. Install RH and LH rack boots, clamps and clips : NOTE: If the hole is clogged, the pressure inside the boot will change after it is assembled and the steering wheel is turned.

2002 STEERING Power Steering System - Corolla

Fig. 109: Locating Steering Rack Hole Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. a. Make sure that the steering rack hole is not clogged with grease. CAUTION: Be careful not to damage or twist the boots.

b. Install the boot clip and a new clamp. c. Using SST, tighten the clamp as shown in the illustration. SST 09521-24010.

2002 STEERING Power Steering System - Corolla

Fig. 110: Tightening Boot Clamps Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. d. Employ the same manner described above to the other side. 17. Install RH and LH tie rod ends and lock nuts : a. Screw the lock nut and tie rod end onto the rack end until the matchmarks are aligned.

2002 STEERING Power Steering System - Corolla

Fig. 111: Aligning Tie Rod End & Rack End Matchmarks Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. After adjusting toe-in, See SPECIFICATIONS & PROCEDURES in ALIGNMENT under STEERING. Torque the nut. Torque: 56 N.m (570 kgf.cm, 41 ft.lbf) 18. Install 2 turn pressure tubes : a. Coat 4 new O-rings with power steering fluid and install them to the 2 turn pressure tubes. NOTE:

Use a torque wrench with a fulcrum length of 250 mm (9.84 in.). This torque value is effective in case that SST is parallel to a torque wrench.

2002 STEERING Power Steering System - Corolla

Fig. 112: Installing Pressure Tubes Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Using SST, install the 2 tubes. Torque: 11 N.m (112 kgf.cm, 8 ft.lbf) . SST 09023-38200. INSTALLATION CAUTION: Do not damage the turn pressure tubes.

2002 STEERING Power Steering System - Corolla

Fig. 113: Installing PS Gear Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 1. Slide the PS gear assembly to the RH of the vehicle, slide the PS gear assembly to the LH side and position it.: 2. Install 2 grommets and brackets a. Install the grommet and bracket with the bolt and nut. Torque: 71 N.m (720 kgf.cm, 52 ft.lbf) . b. Employ the same manner described above to the other side. c. Install the bolt A. Torque: 5.4 N.m (55 kgf.cm, 48 in..lbf) .

2002 STEERING Power Steering System - Corolla

Fig. 114: Locating Bolt "A" Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

Use a torque wrench with a fulcrum length of 300 mm (11.81 in.).

2002 STEERING Power Steering System - Corolla

Fig. 115: Identifying Fulcrum Length & Usage Angle Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

This torque value is effective in case that SST is parallel to a torque wrench.

3. Using SST, connect the pressure feed tube . Torque: 30 N.m (306 kgf.cm, 22 ft.lbf) . SST 0902312700. 4. Connect the return hose with the clip . 5. Install the 2 tube clamps with the 2 bolts . Torque: 5.4 N.m (55 kgf.cm, 48 in..lbf) . 6. Install Rack Boot Heat Insulator Install the rack boot heat insulator with the bolt and nut. Torque: 5.4 N.m (55 kgf.cm, 48 in..lbf) . 7. Install Engine Rear Mount Bracket A131L A/T: Install the engine rear mount bracket with the 2 bolts and drive shaft heat insulator set nut. Torque: Bolt: 77 N.m (790 kgf.cm, 57 ft.lbf) Nut: 17 N.m (168 kgf.cm, 12 ft.lbf) M/T, A245E A/T: Install the engine rear mount bracket with the 3 bolts and drive shaft heat

2002 STEERING Power Steering System - Corolla

insulator set nut. Torque: Bolt: 77 N.m (790 kgf.cm, 57 ft.lbf) Nut: 17 N.m (168 kgf.cm, 12 ft.lbf) 8. Install the engine rear mount insulator to the engine rear mount bracket with the bolt . Torque: 87 N.m (890 kgf.cm, 64 ft.lbf) . 9. Install front sub-frame and lower suspension arm : a. Install the front sub-frame and lower suspension arm with the 14 bolts and 3 nuts.

Fig. 116: Locating Bolts & Nuts Sub-Frame/Lower Suspension Arm Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Torque: Bolt A: 60 N.m (620 kgf.cm, 45 ft.lbf) Bolt B: 64 N.m (650 kgf.cm, 47 ft.lbf) Bolt C: 225 N.m (2,305 kgf.cm, 167 ft.lbf) Bolt D: 147 N.m (1,500 kgf.cm, 109 ft.lbf)

2002 STEERING Power Steering System - Corolla

10. 11. 12. 13.

Bolt E: 175 N.m (1,790 kgf.cm, 129 ft.lbf) Nut: 57 N.m (580 kgf.cm, 42 ft.lbf) b. Remove the engine support fixture. Install the brace with the 2 nuts . Torque: 69 N.m (700 kgf.cm, 51 ft.lbf) . Connect lower ball joint to lower suspension arm . Connect sliding yoke . See 3 in INSTALLATION under STEERING COLUMN. Install Column Hole Cover Install the column hole cover with the 5 bolts. Torque: 4.9 N.m (50 kgf.cm, 43 in..lbf) .

14. Connect RH and LH tie rod ends . See FRONT AXLE HUB & WHEEL BEARING . 15. Install the RH and LH engine under covers with the 8 bolts and 4 screws . NOTE: Do it with the front of the vehicle jacked up.

16. Place front wheels facing straight ahead . 17. Center Spiral Cable . 18. Install steering wheel : a. Align the matchmarks on the steering wheel and steering column main shaft. b. Temporarily tighten the steering wheel set nut. c. Connect the connector. 19. Bleed power steering system. . See REPLACEMENT . 20. Check steering wheel center point . 21. Torque Steering wheel set nut. Torque: 34 N.m (350 kgf.cm, 25 ft.lbf) . 22. Install steering wheel pad. See step 2e in INSPECTION under STEERING WHEEL. 23. Check front wheel alignment . See SPECIFICATIONS & PROCEDURES in WHEEL ALIGNMENT article..

2002 ACCESSORIES/SAFETY EQUIPMENT Toyota - Air Bag Restraint Systems

2002 ACCESSORIES/SAFETY EQUIPMENT Toyota - Air Bag Restraint Systems

DESCRIPTION & OPERATION

WARNING: Accidental air bag deployment is possible. Personal injury may result. Read and follow all WARNINGS and AIR BAG SAFETY PRECAUTIONS before working on air bag system or related components. Supplemental Restraint System (SRS), also known as air bag system, is designed to provide increased accident protection for driver and passenger by deploying air bags in a front-end or side collision. The air bag system is designed to be used in conjunction with 3-point seat belts. The air bag system includes the following components: driver-side air bag module (steering wheel pad), passenger-side air bag module, right and left-side air bag modules, spiral cable, right and left front seat belt pretensioners, AIR BAG warning light, air bag sensor assembly, right and left side air bag sensor assemblies, right and left front air bag sensors and associated wiring harnesses. See COMPONENT LOCATIONS . AIR BAG SENSOR ASSEMBLY The air bag sensor assembly is located on the floor inside lower center finish panel. It consists of an air bag sensor, safing sensor and diagnosis, ignition and drive circuits. It receives signals from the air bag sensor and determines whether air bag modules must be deployed or not. DRIVER-SIDE AIR BAG MODULE The driver-side air bag and inflator is stored in the steering wheel pad. It contains a squib, igniter charge and gas generant and inflates the air bag when instructed by air bag sensor assembly. FRONT AIR BAG SENSOR The front air bag sensors are mounted inside right and left front side members. When sensor detects an impact of sufficient force (above a predetermined limit), contacts inside the sensor close, sending a signal to the air bag sensor assembly. PASSENGER-SIDE AIR BAG MODULE The passenger-side air bag and inflator is stored in the instrument panel above glove box. It contains a squib, igniter charge and gas generant and inflates the air bag when instructed by air bag sensor assembly. SEAT BELT PRETENSIONER The seat belt pretensioner system is a component of the front outer seat belt. It contains a squib, gas generant, wire and piston and operates in the event of a front-end collision. SIDE AIR BAG MODULE The side air bag and inflator is stored in the outboard side of each front seat back. It contains a squib, igniter

2002 ACCESSORIES/SAFETY EQUIPMENT Toyota - Air Bag Restraint Systems

charge and gas generant and inflates the air bag when instructed by respective side air bag sensor assembly. SIDE AIR BAG SENSOR ASSEMBLY The side air bag sensor assembly is mounted in right and left center pillar. It consists of an air bag sensor, safing sensor and diagnosis circuit. It receives signals from the side air bag sensor and determines whether side air bag module must be deployed or not. SPIRAL CABLE The spiral cable is attached to combination switch and is used as an electrical joint between chassis wiring harness and driver-side air bag module. Spiral cable is also known as clockspring.

COMPONENT LOCATIONS
Refer to illustration for component locations. See Fig. 1 .

2002 ACCESSORIES/SAFETY EQUIPMENT Toyota - Air Bag Restraint Systems

Fig. 1: Locating Restraint System Components

2002 ACCESSORIES/SAFETY EQUIPMENT Toyota - Air Bag Restraint Systems

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

SYSTEM OPERATION CHECK

Turn ignition switch to ACC or ON position. AIR BAG warning light should come on for about 6 seconds and then go out. If AIR BAG warning light does not operate as specified, go to DIAGNOSTICS .

AIR BAG SAFETY PRECAUTIONS

Observe the following precautions when servicing air bag system:

Disable air bag system before servicing any air bag system or steering column component. Failure to do this could result in accidental air bag deployment and possible personal injury. See DISABLING & ACTIVATING AIR BAG SYSTEM . When diagnosing air bag system, always check for diagnostic trouble codes before disconnecting battery. After turning ignition switch to LOCK position and disconnecting negative battery cable, wait at least 90 seconds before working on air bag system. Air bag system is equipped with a back-up power source that may allow air bag to deploy until 90 seconds after disconnecting negative battery cable. If vehicle was in a minor collision but air bags did not deploy, inspect all system components for any sign of damage, and replace as necessary. Never use air bag system components from another vehicle. Replace air bag system components with new parts. Remove air bag sensor assembly and side air bag sensors, if repairing the vehicle requires impacting (shocking) the vehicle. Never disassemble or repair air bag sensor assembly, passenger-side air bag module, side air bag module or driver-side air bag module. Replace dropped, cracked, dented or otherwise damaged components. DO NOT expose air bag sensor assembly, driver-side, passenger-side or side air bag module directly to heat or flame. When diagnosing electrical circuits, use a volt/ohm meter with high impedance (10,000 ohms minimum). Information labels are attached to air bag components. Follow all notices on labels. After work on air bag system is complete, check AIR BAG warning light to ensure system is functioning properly. See SYSTEM OPERATION CHECK . Always wear safety glasses when servicing or handling an air bag. When placing a live air bag on a bench or other surface, always face air bag and trim cover up and away from surface. This will reduce motion of module if it is accidentally deployed. After deployment, air bag surface may contain deposits of sodium hydroxide, which irritates skin. Always wear safety glasses, rubber gloves, and long-sleeved shirt during clean- up. After clean up, wash hands using mild soap and water. Carry a live air bag module with trim cover (air bag) pointed away from your body to minimize injury in case accidental deployment. If air bag system is not fully functional for any reason, vehicle should not be driven until system is repaired and again becomes operational. DO NOT remove bulbs, modules, sensors or other components, or in any way disable system from operating normally. If air bag system is not

2002 ACCESSORIES/SAFETY EQUIPMENT Toyota - Air Bag Restraint Systems

functional, park vehicle until it is repaired and functions properly.

ADJUSTMENTS
SPIRAL CABLE Ensure front wheels are in straight-ahead position. Turn spiral cable counterclockwise until it becomes difficult to turn. Turn spiral cable clockwise about 3 turns and align match marks. See Fig. 2 .

Fig. 2: Adjusting Spiral Cable (Typical) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

DISABLING & ACTIVATING AIR BAG SYSTEM

WARNING: Unintentional air bag module deployment is possible. Personal injury may result. Never use memory savers when working on air bag system. Unintentional air bag module deployment is possible. Personal injury may result. Back-up power supply maintains air bag system voltage for about 90 seconds after battery is disconnected. After disabling air bag system, wait at least 90 seconds before servicing air bag system.

2002 ACCESSORIES/SAFETY EQUIPMENT Toyota - Air Bag Restraint Systems

DISABLING SYSTEM
For Component Replacement

Turn ignition switch to LOCK position. Disconnect and shield negative battery cable. Wait at least 90 seconds before starting any work on vehicle.
For Diagnostics

1. Turn ignition switch to LOCK position. Disconnect and shield negative battery cable. Wait at least 90 seconds. Remove driver-side air bag module. See DRIVER-SIDE AIR BAG MODULE under REMOVAL & INSTALLATION. Disconnect passenger-side air bag module connector, accessible by removing glove box. See Fig. 3 . 2. Disconnect air bag sensor assembly connector. See AIR BAG SENSOR ASSEMBLY under REMOVAL & INSTALLATION. Disconnect right and left seat belt pretensioner connectors. See SEAT BELT PRETENSIONER under REMOVAL & INSTALLATION. Disconnect right-side and left-side air bag module connectors. See SIDE AIR BAG MODULE under REMOVAL & INSTALLATION. 3. Disconnect right and left-side air bag sensor connectors. See SIDE AIR BAG SENSOR ASSEMBLY under REMOVAL & INSTALLATION. Disconnect right and left front air bag sensor connectors. See FRONT AIR BAG SENSOR under REMOVAL & INSTALLATION.

2002 ACCESSORIES/SAFETY EQUIPMENT Toyota - Air Bag Restraint Systems

Fig. 3: Disconnecting Passenger-side Air Bag Module Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ACTIVATING SYSTEM
For Component Replacement

Ensure ignition switch is in LOCK position. Reconnect negative battery cable. Perform SYSTEM OPERATION CHECK .
For Diagnostics

1. Turn ignition switch to LOCK position. Disconnect and shield negative battery cable. Wait at least 90 seconds. Install driver-side air bag module. Reconnect passenger-side air bag module connector. Connect air bag sensor assembly connector. 2. Connect right and left front air bag sensor connectors. Connect right and left seat belt pretensioner connectors. Connect right and left-side air bag module connectors. Connect right and left-side air bag sensor connectors. Reconnect negative battery cable. Perform SYSTEM OPERATION CHECK .

DISPOSAL PROCEDURES
WARNING: Undeployed air bags contain substances that can cause illness or injury if improperly handled. Disposing of an undeployed air bag may violate federal, state and/or local laws. If scrapping vehicle, air bag must be deployed while still mounted in vehicle. Air bags should not be deployed inside vehicle unless vehicle is to be scrapped. If not scrapping vehicle, use off-vehicle deployment procedures. See OFFVEHICLE DEPLOYMENT . Wear gloves and safety glasses when handling air bag. Wrap deployed air bag in a sturdy plastic bag and dispose of it like any other part. ON-VEHICLE DEPLOYMENT (SCRAPPED VEHICLES ONLY)
Driver-side & Passenger-side AIR Bag Module

1. Before proceeding, see AIR BAG SAFETY PRECAUTIONS . Disconnect negative battery cable. Ensure steering wheel, driver-side air bag and passenger-side air bag modules are not loose. If components are loose, remove and deploy air bag(s) using OFF-VEHICLE DEPLOYMENT procedure. 2. If deploying driver-side air bag module, disconnect Yellow lower spiral cable connector under lower steering column. If deploying passenger-side air bag, disconnect Yellow passenger-side air bag connector, accessible by removing glove box assembly. See Fig. 3 . 3. For driver-side air bag, connect Deployment Tool (09082-00700) to spiral cable connector. For passenger-side air bag, connect Deployment Tools (09082-00700 and 09082-00760) to air bag connector. On both modules, position deployment tool at least 33 feet from front of vehicle. Close all doors and windows of vehicle. 4. Connect deployment tool Red clip to positive battery terminal and Black clip to negative battery terminal. Ensure no one is inside vehicle or within 33 feet of vehicle. Press activation switch to deploy air bag. Because of heat, DO NOT touch air bag for at least 30 minutes after deployment. Scrap

2002 ACCESSORIES/SAFETY EQUIPMENT Toyota - Air Bag Restraint Systems

vehicle with air bag(s) still installed.

Side AIR Bag Module

1. Before proceeding, see AIR BAG SAFETY PRECAUTIONS . Disconnect negative battery cable. Ensure seat back is not loose. If components are loose, remove and deploy air bag(s) using OFFVEHICLE DEPLOYMENT procedure. Disconnect appropriate side air bag connector, located under seat. 2. Connect Deployment Tools (09082-00700 and 09082-00750) to appropriate air bag connector. Position deployment tool at least 33 feet from front of vehicle. Close all doors and windows of vehicle. Connect deployment tool Red clip to positive battery terminal and Black clip to negative battery terminal. 3. Ensure no one is inside vehicle or within 33 feet of vehicle. Press activation switch to deploy air bag. Because of heat, DO NOT touch air bag for at least 30 minutes after deployment. Scrap vehicle with air bag(s) still installed.
Seat Belt Pretensioner

1. Before proceeding, see AIR BAG SAFETY PRECAUTIONS . Disconnect negative battery cable. Ensure seat belt pretensioner is not loose. If components are loose, remove and deploy using OFFVEHICLE DEPLOYMENT procedure. Disconnect appropriate seat belt pretensioner connector. See SEAT BELT PRETENSIONER under REMOVAL & INSTALLATION. 2. Connect Deployment Tools (09082-00700 and 09082-00740) to appropriate seat belt pretensioner connector. Position deployment tool at least 33 feet from front of vehicle. Close all doors and windows of vehicle. Connect deployment tool Red clip to positive battery terminal and Black clip to negative battery terminal. 3. Ensure no one is inside vehicle or within 33 feet of vehicle. Press activation switch to deploy air bag. Because of heat, DO NOT touch pretensioner for at least 30 minutes after deployment. Scrap vehicle with pretensioner(s) still installed. OFF-VEHICLE DEPLOYMENT
Driver-side AIR Bag Module

1. Before proceeding, see AIR BAG SAFETY PRECAUTIONS . Disconnect negative battery cable. Remove driver-side air bag module. See DRIVER-SIDE AIR BAG MODULE under REMOVAL & INSTALLATION. 2. Install 2 bolts (6 mm X 35 mm) with washers into holes located in rear of air bag module and tighten bolts by hand. DO NOT overtighten bolts. Wrap strong wire at least twice around each bolt. See Fig. 4 . Ensure no slack is present in wire. If slack is present, or wire is not strong enough, driver-side air bag module may become loose due to shock when air bag deploys. 3. Position driver-side air bag module on rim of a scrap tire and wheel assembly with pad side facing upward. See Fig. 5 . Securely tie air bag module to wheel rim through lug nut holes. Place a large cardboard box (weighted with at least 44 lbs. at sides) or 3 scrap tires on top of air bag module. 4. Connect Deployment Tool (09082-00700) to air bag module connector. Position deployment tool at least 33 feet away from air bag module. Press activation switch to deploy air bag. Because of heat, wait 30 minutes before handling driver-side air bag module. Seal deployed air bag in vinyl bag and dispose of in usual manner.

2002 ACCESSORIES/SAFETY EQUIPMENT Toyota - Air Bag Restraint Systems

Fig. 4: Securing Wire To Driver-side Air Bag Module Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 ACCESSORIES/SAFETY EQUIPMENT Toyota - Air Bag Restraint Systems

Fig. 5: Securing Driver-side Air Bag Module To Wheel Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Passenger-side AIR Bag Module

1. Before proceeding, see AIR BAG SAFETY PRECAUTIONS . Disconnect negative battery cable. Remove passenger-side air bag. See PASSENGER-SIDE AIR BAG MODULE under REMOVAL & INSTALLATION. 2. Wind strong wire around each passenger-side air bag mounting bracket. Position air bag inside scrap tire with air bag trim cover facing inside if tire and secure with remaining wire. See Fig. 6 . Place this tire between 4 other tires (top tire should have wheel installed). Securely tie all tires together with wire. 3. Connect Deployment Tools (09082-00700 and 09082-00760) to passenger-side air bag connector. Position deployment tool at least 33 feet away from passenger-side air bag. Press activation switch to deploy passenger-side air bag. Because of heat, wait 30 minutes before handling passenger-side air bag. Seal deployed air bag in vinyl bag and dispose of in usual manner.

2002 ACCESSORIES/SAFETY EQUIPMENT Toyota - Air Bag Restraint Systems

Fig. 6: Preparing Air Bag For Deployment Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Side AIR Bag Module

1. Before proceeding, see AIR BAG SAFETY PRECAUTIONS . Disconnect negative battery cable. Remove appropriate side air bag. See SIDE AIR BAG MODULE . Install 2 nuts on stud located on

2002 ACCESSORIES/SAFETY EQUIPMENT Toyota - Air Bag Restraint Systems

rear of air bag module. Wrap strong wire at least twice around each stud. See Fig. 7 . Ensure no slack is present in wire. 2. Position side air bag inside a scrap tire with air bag deployment direction facing inside and secure with strong wire. See Fig. 8 . Place this tire between 4 other tires (top tire should have wheel installed). Securely tie all tires together with wire. 3. Connect Deployment Tools (09082-00700 and 09082-00750) to side air bag connector. Position deployment tool at least 33 feet away from side air bag. Press activation switch to deploy side air bag. Because of heat, wait 30 minutes before handling side air bag. Seal deployed air bag in vinyl bag and dispose of in usual manner.

Fig. 7: Securing Wire To Side Air Bag Module Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 ACCESSORIES/SAFETY EQUIPMENT Toyota - Air Bag Restraint Systems

Fig. 8: Preparing Side Air Bag For Deployment Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Pretensioner

1. Before proceeding, see AIR BAG SAFETY PRECAUTIONS . Disconnect negative battery cable. Remove appropriate seat belt pretensioner. See SEAT BELT PRETENSIONER under REMOVAL & INSTALLATION. 2. Connect Deployment Tools (09082-00700 and 09082-00740) to seat belt pretensioner connector. Position seat belt pretensioner on ground an cover with wheel and tire assembly. See Fig. 9 . Position deployment tool at least 33 feet away from seat belt pretensioner. Press activation switch to deploy seat belt pretensioner. Because of heat, wait 30 minutes before handling. Dispose of deployed pretensioner in usual manner.

2002 ACCESSORIES/SAFETY EQUIPMENT Toyota - Air Bag Restraint Systems

Fig. 9: Deploying Seat Belt Pretensioner Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

POST-COLLISION INSPECTION
When a vehicle has been involved in a collision, certain components of the passive restraint system must be inspected or replaced. See AIR BAG/SRS COMPONENT INSPECTION & REPLACEMENT TABLES article in the GENERAL INFORMATION section.

REMOVAL & INSTALLATION

WARNING: Unintentional air bag module deployment is possible. Personal injury may result. Never use memory savers when working on air bag system. Unintentional air bag module deployment is possible. Failure to follow service precautions may result in air bag deployment and personal injury. Read and carefully follow all WARNINGS and AIR BAG SAFETY PRECAUTIONS before working on air bag system or related components. See AIR BAG SAFETY PRECAUTIONS . After component replacement, check system operation. See SYSTEM OPERATION CHECK .

2002 ACCESSORIES/SAFETY EQUIPMENT Toyota - Air Bag Restraint Systems

AIR BAG SENSOR ASSEMBLY NOTE: Disconnect and connect air bag sensor assembly connectors with sensor assembly mounted on vehicle.

Removal & Installation

1. Before proceeding, see AIR BAG SAFETY PRECAUTIONS . Turn ignition switch to LOCK position. Disconnect and shield negative battery cable. Wait at least 90 seconds. Air bag sensor is located on the floor inside lower center finish panel. See Fig. 1 . 2. Remove front scuff plates and cowl side trims. Remove lower finish panel and lower left insert. See Fig. 10 . Remove lower panel and lower right panel. Remove center cluster finish panel and stereo opening cover. Remove shift hole bezel (A/T) or shifting hole cover (M/T). 3. Remove rear console box and lower center finish panel. Disconnect air bag sensor electrical connector. Remove 3 Torx screws and air bag sensor assembly. 4. To install, reverse removal procedure. Tighten air bag sensor assembly screws to specification. See TORQUE SPECIFICATIONS . Check AIR BAG warning light to ensure system is functioning properly. See SYSTEM OPERATION CHECK .

2002 ACCESSORIES/SAFETY EQUIPMENT Toyota - Air Bag Restraint Systems

Fig. 10: Identifying Air Bag Sensor Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. DRIVER-SIDE AIR BAG MODULE
Removal & Installation

1. Before proceeding, see AIR BAG SAFETY PRECAUTIONS . Turn ignition switch to LOCK position. Disconnect and shield negative battery cable. Wait at least 90 seconds. Ensure front wheels are in straight-ahead position.

2002 ACCESSORIES/SAFETY EQUIPMENT Toyota - Air Bag Restraint Systems

2. Remove screw covers from back side of steering wheel for access to air bag module retaining screws. See Fig. 11 . Loosen Torx screws until groove around screw circumference catches on screw case. 3. Pull driver-side air bag module from steering wheel and disconnect air bag module connector. Place air bag module on a flat surface with pad cover facing up. NOTE: If horn button contact plate of steering wheel is deformed, replace steering wheel assembly.

4. To install, reverse removal procedure. There should be no interference between air bag module and steering wheel, and clearance should be uniform all the way around. Tighten air bag module screws to specification. See TORQUE SPECIFICATIONS . Check AIR BAG warning light to ensure system is functioning properly. See SYSTEM OPERATION CHECK .

2002 ACCESSORIES/SAFETY EQUIPMENT Toyota - Air Bag Restraint Systems

Fig. 11: Identifying Driver-side Air Bag Module Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. FRONT AIR BAG SENSOR NOTE: Disconnect and connect front air bag sensor connector with sensor mounted on vehicle.

2002 ACCESSORIES/SAFETY EQUIPMENT Toyota - Air Bag Restraint Systems

Removal & Installation

1. Before proceeding, see AIR BAG SAFETY PRECAUTIONS . Turn ignition switch to LOCK position. Disconnect and shield negative battery cable. Wait at least 90 seconds. 2. For left front air bag sensor, remove left engine under cover. Disconnect left front air bag sensor connector. Remove 2 bolts and remove sensor. 3. For right front air bag sensor, remove right front turn signal lamp assembly. Remove right headlight assembly. Disconnect right front air bag sensor connector. Remove 2 bolts and remove sensor. 4. To install, reverse removal procedure. Tighten front air bag sensor bolts to specification. See TORQUE SPECIFICATIONS . Check AIR BAG warning light to ensure system is functioning properly. See SYSTEM OPERATION CHECK . PASSENGER-SIDE AIR BAG MODULE
Removal & Installation

1. Before proceeding, see AIR BAG SAFETY PRECAUTIONS . Turn ignition switch to LOCK position. Disconnect and shield negative battery cable. Wait at least 90 seconds. Remove right front door scuff plate and cowl side trim. See Fig. 12 . 2. Remove lower panel (glove box assembly). Disconnect passenger-side air bag module connector. See Fig. 3 . Remove 2 bolts and 2 nuts and passenger-side air bag module. Place air bag module on a flat surface with pad cover facing up. NOTE: If instrument panel or instrument panel reinforcement is deformed or cracked, replace with new part.

3. To install, reverse removal procedure. Tighten fasteners to specification. See TORQUE SPECIFICATIONS . There should be no interference between instrument panel and passenger-side air bag module, and clearance should be uniform all the way around. Check AIR BAG warning light to ensure system is functioning properly. See SYSTEM OPERATION CHECK .

2002 ACCESSORIES/SAFETY EQUIPMENT Toyota - Air Bag Restraint Systems

Fig. 12: Identifying Passenger-side Air Bag Module Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. SIDE AIR BAG MODULE
Removal

1. Before proceeding, see AIR BAG SAFETY PRECAUTIONS . Turn ignition switch to LOCK position. Disconnect and shield negative battery cable. Wait at least 90 seconds. Remove 2 seat track covers and 4 bolts. See Fig. 13 . Disconnect side air bag module connector and remove seat. 2. Remove headrest, reclining adjuster release handle, front seat cushion and inner front seat cushion shield. Fold seat back forward and remove side air bag wire harness from wire harness protector. Remove hog rings from bottom of seat back. Remove 4 bolts and seat back assembly. 3. Fold seat back cover up and remove hook from seat back frame. Remove 2 hog rings. Remove

2002 ACCESSORIES/SAFETY EQUIPMENT Toyota - Air Bag Restraint Systems

headrest supports. Remove seat back frame from seat back cover. Remove 2 nuts and remove side air bag module.

Fig. 13: Identifying Side Air Bag Module (Left Seat Shown; Right Seat Is Similar) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Installation

To install, reverse removal procedure. Tighten fasteners to specification. See TORQUE SPECIFICATIONS . Check AIR BAG warning light to ensure system is functioning properly. See

2002 ACCESSORIES/SAFETY EQUIPMENT Toyota - Air Bag Restraint Systems

SYSTEM OPERATION CHECK . SIDE AIR BAG SENSOR ASSEMBLY

Removal & Installation

1. Before proceeding, see AIR BAG SAFETY PRECAUTIONS . Turn ignition switch to LOCK position. Disconnect and shield negative battery cable. Wait at least 90 seconds. Remove front door scuff plate and center pillar lower garnish. Disconnect pretensioner connector and retractor switch connectors. 2. Remove 2 bolts and pretensioner/retractor assembly. Disconnect side air bag sensor assembly connector. Using Torx wrench (T40), remove 4 screws and side air bag sensor assembly. 3. To install, reverse removal procedure. Tighten fasteners to specification. See TORQUE SPECIFICATIONS . Check AIR BAG warning light to ensure system is functioning properly. See SYSTEM OPERATION CHECK . SEAT BELT PRETENSIONER
Removal & Installation

1. Before proceeding, see AIR BAG SAFETY PRECAUTIONS . Turn ignition switch to LOCK position. Disconnect and shield negative battery cable. Wait at least 90 seconds. Remove front door scuff plate. Remove center pillar lower garnish. Disconnect pretensioner connector and retractor switch connectors. Remove 2 bolts and pretensioner/retractor assembly. 2. To install, reverse removal procedure. Tighten fasteners to specification. See TORQUE SPECIFICATIONS . Check AIR BAG warning light to ensure system is functioning properly. See SYSTEM OPERATION CHECK . SPIRAL CABLE
Removal

Before proceeding, see AIR BAG SAFETY PRECAUTIONS . Turn ignition switch to LOCK position. Disconnect and shield negative battery cable. Wait at least 90 seconds. Remove driver-side air bag module. See DRIVER-SIDE AIR BAG MODULE . Remove steering wheel. See STEERING WHEEL . Remove lower finish panel assembly. Remove upper and lower steering column covers. Remove 4 screws and spiral cable from combination switch. WARNING: Spiral cable mating marks must be properly aligned or steering wheel may not turn completely, or flat cable inside spiral cable may be severed, disabling air bag system
Installation

To install, reverse removal procedure. Ensure front wheels are in straight-ahead position and spiral cable is properly aligned. See SPIRAL CABLE under ADJUSTMENTS. Tighten fasteners to specification. See TORQUE SPECIFICATIONS . Check AIR BAG warning light to ensure system is functioning properly. See SYSTEM OPERATION CHECK . STEERING WHEEL

2002 ACCESSORIES/SAFETY EQUIPMENT Toyota - Air Bag Restraint Systems

Removal & Installation

1. Before proceeding, see AIR BAG SAFETY PRECAUTIONS . Turn ignition switch to LOCK position. Disconnect and shield negative battery cable. Wait at least 90 seconds. Ensure front wheels are in straight-ahead position. 2. Remove driver-side air bag module. See DRIVER-SIDE AIR BAG MODULE . Remove steering wheel retaining nut. Place match marks on steering wheel and steering column shaft for reassembly reference. Using appropriate puller, pull steering wheel from steering column shaft. 3. To install, reverse removal procedure. Ensure front wheels are in straight-ahead position and spiral cable is properly aligned. See SPIRAL CABLE under ADJUSTMENTS. Tighten steering wheel retaining nut to specification. See TORQUE SPECIFICATIONS . Check AIR BAG warning light to ensure system is functioning properly. See SYSTEM OPERATION CHECK .

DIAGNOSTICS
WARNING: Unintentional air bag module deployment is possible. Personal injury may result. Never use memory savers when working on air bag system. AIR BAG WARNING LIGHT CHECK Turn ignition switch to ACC or ON position. If AIR BAG warning comes on for about 6 seconds and then goes off, system is functioning properly. If AIR BAG warning light comes on and does not go off or flashes, Diagnostic Trouble Code (DTC) is stored in air bag sensor assembly memory. Proceed to RETRIEVING CODES . If AIR BAG warning light responds in any other way, go to DIAGNOSTIC TESTS . RETRIEVING CODES CAUTION: Air bag system damage possible. System may be damaged if jumper wire is incorrectly connected across terminals of Data Link Connector (DLC). Use Diagnosis Check Wire (09843-18020) when connecting terminals of DLC.
Using Diagnosis Check Wire

1. Turn ignition switch to ACC or ON position. Wait about 20 seconds. Using Diagnosis Check Wire (09843-18020), connect terminals Tc and E1 of Data Link Connector 1 (DLC1). DLC1 is located in left rear of engine compartment near brake booster. See Fig. 2 . 2. If AIR BAG warning light flashes 2 times per second, system is normal (normal code). If AIR BAG warning light does not flash Diagnostic Trouble Codes (DTCs) or flashes DTCs without DLC1 connection, see DTCS NOT DISPLAYED or DTCS CONTINUOUSLY DISPLAYED under DIAGNOSTIC TESTS. If AIR BAG warning light is on continuously and DTC is normal (flashes 2 times per second), source voltage is low. Go to SOURCE VOLTAGE DROP under DIAGNOSTIC TESTS. 3. If AIR BAG warning light flashes, count number of flashes to determine DTCs that are set. For example, DTC 12 is: FLASH, 1.5-second pause, FLASH, FLASH. If more than one DTC is displayed, a 2.5-second pause will occur between each DTC. Lowest numbered DTC will be displayed first, followed by next higher number DTC until all DTCs have been displayed. 4. After all DTCs are displayed, a 4-second pause will occur, and DTC display will be repeated. See

2002 ACCESSORIES/SAFETY EQUIPMENT Toyota - Air Bag Restraint Systems

appropriate DTC under DIAGNOSTIC TESTS . After repairing, clear DTCs. See CLEARING CODES . NOTE: If DTCs other than those listed under DIAGNOSTIC TESTS are displayed, replace the air bag sensor assembly. If the AIR BAG warning light does not function as described, proceed to appropriate test under DIAGNOSTIC TESTS .

Fig. 14: Identifying Data Link Connector 1 (DLC1) Terminals Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Using Toyota Hand-held Tester

Install Toyota hand-held tester to DLC1 or DLC3. DLC1 is located in left rear of engine compartment near brake booster. See Fig. 14 . DLC3 is located under left side of instrument panel. Read DTC by following prompts on tester. See tester operator's manual for complete instructions. CLEARING CODES
Using Jumper Wire

1. Use 2 jumper wires. Connect one end of first jumper wire to DLC1 terminal Tc and one end of second

2002 ACCESSORIES/SAFETY EQUIPMENT Toyota - Air Bag Restraint Systems

jumper wire to DLC1 terminal AB. See Fig. 14 . Turn ignition switch to ACC or ON position. Wait about 6 seconds. NOTE: When alternately grounding terminals Tc and AB, release ground from one terminal and immediately ground the other terminal within 0.2 second. If time interval exceeds 0.2 second, DTCs will not be cleared.

2. Starting with jumper wire connected to terminal Tc, apply body ground alternately to terminal Tc and terminal AB twice each, in cycles of 1/2 to 1 1/2 seconds (sequence is: Tc, AB, Tc, AB). Finally, keep applying body ground to terminal Tc until AIR BAG warning light flashes quickly, indicating DTCs are cleared.
Using Toyota Hand-held Tester

Connect Toyota hand-held tester to DLC1 or DLC3. DLC1 is located in left rear of engine compartment near brake booster. DLC3 is located under left side of instrument panel. Clear DTCs by following prompts on tester. See tester operator's manual for complete instructions. RELEASING SHORTING SPRING CAUTION: Damage to air bag electrical connector terminal is possible. If paper thicker than male terminal is used, connector terminal could be damaged. Damaged connector terminal could result in system fault. Always use paper that is same thickness as male terminal. NOTE: Perform this procedure only if you were sent here from DIAGNOSTIC TESTS.

1. Air bag squib circuit consists of circuit between air bag sensor assembly and air bag. If voltage is accidentally applied across squib circuit (as when testing, for example), air bag will deploy. 2. To prevent accidental deployment, squib circuit connectors contain a spring-loaded shorting bar (shorting spring). When squib circuit connector is disconnected, shorting spring automatically shorts squib circuit positive and negative circuits together. This prevents air bag deployment if voltage is accidentally applied across squib circuit. 3. When connector halves are attached, shorting bar is in released position (no continuity exists between terminals). When connector is disconnected, shorting bar is engaged (continuity exists between terminals). 4. Some testing procedures require shorting spring to be in released position with connector disconnected (this is opposite of its normal position). To hold shorting spring in released position, obtain a piece of paper that is same thickness as male terminal blade that slides under shorting spring when the connector is connected. See Fig. 15 . 5. With squib circuit connector disconnected, insert paper into female terminal, sliding it under shorting spring. This lifts spring, breaking circuit and allowing test procedure to be performed.

2002 ACCESSORIES/SAFETY EQUIPMENT Toyota - Air Bag Restraint Systems

2002 ACCESSORIES/SAFETY EQUIPMENT Toyota - Air Bag Restraint Systems

Fig. 15: Releasing Shorting Spring Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

DIAGNOSTIC TESTS
WARNING: Unintentional air bag module deployment is possible. Failure to follow service precautions may result in air bag deployment and personal injury. Read and carefully follow all WARNINGS and AIR BAG SAFETY PRECAUTIONS before working on air bag system component or related components. See AIR BAG SAFETY PRECAUTIONS . After component replacement, check system operation. See SYSTEM OPERATION CHECK . CAUTION: Damage to air bag sensor is possible. Disconnecting negative battery cable with ignition switch in ON or ACC position can damage air bag sensor. Ensure ignition switch is in LOCK position before disconnecting or connecting negative battery cable. Air bag system wiring and connector terminals can be easily damaged. Probing directly on connector terminals and through air bag system wiring insulation can cause damage to air bag electrical system. This can result in air bag system malfunction. To prevent damage to connector terminals and wiring when testing, backprobe terminals (probe terminal where wire enters harness connector). NOTE: In the following tests, the term squib connector and module connector may be used interchangeably.

AIR BAG WARNING LIGHT DOES NOT ILLUMINATE

Description

AIR BAG warning light is located in instrument cluster. When air bag system is normal, AIR BAG warning light illuminates for about 6 seconds after ignition switch is turned from LOCK to ACC or ON position, and turns off automatically. If a malfunction is present in air bag system, AIR BAG warning light illuminates to inform operator of malfunction. When Data Link Connector 1 (DLC1) terminals Tc and E1 are connected together, a Diagnostic Trouble Code (DTC) is displayed by flashing of AIR BAG warning light.
Diagnostic Procedure

1. Remove ECU-B fuse and check continuity across fuse blades. ECU-B fuse is located in instrument panel fuse block at left side of instrument panel. If fuse is faulty, go to step 4 . If fuse is okay, reinstall fuse and go to next step. 2. Disable air bag system. See DISABLING SYSTEM under DISABLING & ACTIVATING AIR BAG SYSTEM. Reconnect negative battery cable. Turn ignition switch to ACC or ON position. Measure voltage between ground and air bag sensor assembly connector C5, terminal No. 2 (circuit LA, Black/Yellow wire). See Fig. 16 . If 10-14 volts is not present, repair AIR BAG warning light bulb or circuit. If 10-14 volts is present, go to next step. 3. Turn ignition switch to LOCK position. Disconnect negative battery cable. Reconnect air bag sensor assembly connectors. Reconnect negative battery cable and wait at least 2 seconds. Turn ignition

2002 ACCESSORIES/SAFETY EQUIPMENT Toyota - Air Bag Restraint Systems

switch to ACC or ON position. If AIR BAG warning light operation is okay, system operation is normal. If AIR BAG warning light does not come on, check for poor connection at air bag sensor assembly connector C5, terminal No. 2 (Black/Yellow wire). If connection is okay, replace air bag sensor assembly. 4. Recheck ECU-B fuse. If fuse is blown, check harness between ECU-B fuse and AIR BAG warning light. If fuse is okay, check for intermittent fault. See AIR BAG WARNING LIGHT INTERMITTENT .

Fig. 16: Identifying Air Bag Sensor Assembly Connectors Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. AIR BAG WARNING LIGHT IS ILLUMINATED WITH IGNITION OFF
Description

AIR BAG warning light is located in instrument cluster. When air bag system is normal, AIR BAG warning light illuminates for about 6 seconds after ignition switch is turned from LOCK to ACC or ON position, and turns off automatically. If a malfunction is present in air bag system, AIR BAG warning light illuminates to inform operator of malfunction. When Data Link Connector 1 (DLC1) terminals Tc and E1 are connected together, a Diagnostic Trouble Code (DTC) is displayed by flashing of AIR BAG warning light.
Diagnostic Procedure

Disable air bag system. See DISABLING SYSTEM under DISABLING & ACTIVATING AIR BAG SYSTEM. Reconnect negative battery cable. Perform SYSTEM OPERATION CHECK . If AIR BAG warning light does not illuminate, replace air bag sensor assembly. If AIR BAG warning light is still illuminated, repair AIR BAG warning light circuit Black/Yellow wire or circuit AB (Black/Yellow wire) leading to the DLC1. See WIRING DIAGRAMS . AIR BAG WARNING LIGHT INTERMITTENT

2002 ACCESSORIES/SAFETY EQUIPMENT Toyota - Air Bag Restraint Systems

If AIR BAG warning light comes on intermittently, perform following tests to simulate driving conditions. If problem cannot be found, replace all components including wiring harness.

Wiggle-test wiring harness. Apply heat to components with a hair dryer. Spray water onto entire vehicle (not directly onto electrical components) to simulate humidity.

DTCS NOT DISPLAYED NOTE: Use following procedure if DTCs are not displayed or AIR BAG warning light stays on when jumper wire is connected between terminals Tc and E1 of DLC1.

Description

When DLC1 terminals Tc and E1 are connected together, air bag sensor assembly is set in Diagnostic Trouble Code (DTC) output mode. DTC is displayed by flashing of AIR BAG warning light.
Diagnostic Procedure

1. Turn ignition switch from LOCK to ACC or ON position. If AIR BAG warning light does not illuminate for about 6 seconds, repair AIR BAG warning light circuit. See WIRING DIAGRAMS . If AIR BAG warning light illuminates for about 6 seconds, go to next step. 2. Measure voltage between DLC1 terminals Tc and E1. See Fig. 14 . If 10-14 volts is present, go to step 4 . If 10-14 volts is not present, go to next step. 3. Measure voltage between ground and DLC1 terminal Tc. If 10-14 volts is present, repair harness between ground and DLC1 terminal E1. See WIRING DIAGRAMS . If 10-14 volts is not present, go to next step. 4. Turn ignition switch to LOCK position. Disconnect negative battery cable and wait at least 90 seconds. Access and disconnect air bag sensor assembly connector C5 (center connector). See AIR BAG SENSOR ASSEMBLY under REMOVAL & INSTALLATION. Connect one end of jumper wire to harness side of air bag sensor assembly connector C5, terminal No. 15 (Circuit Tc, Pink/Black wire). See Fig. 16 . Leave other end of jumper wire disconnected. Reconnect air bag sensor assembly connector with jumper wire connected. Connect negative battery cable and turn ignition switch to ACC or ON position. Wait at least 20 seconds. Connect unconnected end of jumper wire to ground. If AIR BAG warning light does not illuminate, replace air bag sensor assembly. If AIR BAG warning light illuminates, check Pink/Black wire between air bag sensor assembly and DLC1. DTCS CONTINUOUSLY DISPLAYED NOTE: Use following procedure if DTCs are displayed without connecting jumper wire between terminals Tc and E1 of DLC1.

Description

When DLC1 terminals Tc and E1 are connected together, air bag sensor assembly is set in Diagnostic Trouble Code (DTC) output mode. DTC is displayed by flashing of AIR BAG warning light.
Diagnostic Procedure

2002 ACCESSORIES/SAFETY EQUIPMENT Toyota - Air Bag Restraint Systems

1. Turn ignition switch to LOCK position. Disconnect negative battery cable. Wait at least 90 seconds. Access and disconnect air bag sensor assembly connector C5 (center connector). See AIR BAG SENSOR ASSEMBLY under REMOVAL & INSTALLATION. 2. Measure resistance between ground and air bag sensor assembly connector C5, terminal No. 15 (circuit Tc, Pink/Black wire). See Fig. 16 . If resistance is more than one megohm, replace air bag sensor assembly. If resistance is less than one megohm, replace harness or connector. SOURCE VOLTAGE DROP
Description

The air bag sensor assembly is equipped with a voltage-increase circuit to allow system operation in case source (battery) voltage drops below minimum. When battery voltage drops, voltage-increase circuit functions to increase voltage of air bag system to normal voltage. The malfunction display for this circuit is different from other air bag system circuits. When source voltage drop is detected and no other DTCs are present, the AIR BAG warning light remains illuminated constantly. Source voltage drop is not recorded in air bag sensor assembly as a malfunction, and when source voltage returns to normal, AIR BAG warning light will turn off.
Diagnostic Procedure

1. Turn ignition switch to LOCK position. Disable air bag system. See DISABLING SYSTEM under DISABLING & ACTIVATING AIR BAG SYSTEM. Reconnect negative battery cable. 2. Turn ignition switch to ON position. Turn on electrical accessories (defogger, wipers, headlights, blower motor, etc.). Measure voltage independently between ground and air bag sensor assembly connector C5, terminals No. 3 (circuit IG2, Black/Orange wire) and No. 4 (circuit ACC, Gray wire). See Fig. 16 . Turn electrical accessories off. If voltage is 10-14 volts, go to next step. If voltage is not 10-14 volts, check harness between battery and air bag sensor assembly and check battery and charging system. See WIRING DIAGRAMS . 3. Turn ignition switch to LOCK position. Activate air bag system. See ACTIVATING SYSTEM under DISABLING & ACTIVATING AIR BAG SYSTEM. Turn ignition switch to ON position. Turn on electrical accessories again. If AIR BAG warning light goes out, system operation is normal at this time. Check for intermittent fault. See AIR BAG WARNING LIGHT INTERMITTENT . If AIR BAG warning light does not go out, check for DTCs. See RETRIEVING CODES under DIAGNOSTICS. If DTC is displayed, go to appropriate DTC. If a normal code is displayed (2 flashes per second), replace air bag sensor assembly. DTC 11/B0102: DRIVER-SIDE AIR BAG SQUIB CIRCUIT SHORT TO GROUND
Description

The driver-side air bag squib circuit consists of the air bag sensor assembly, spiral cable and driver-side air bag module. The squib causes driver-side air bag to deploy when all deployment conditions are satisfied.
Possible Causes

DTC 11/B0102 could be caused by a short to ground in squib circuit, squib malfunction, spiral cable malfunction or air bag sensor assembly malfunction.

2002 ACCESSORIES/SAFETY EQUIPMENT Toyota - Air Bag Restraint Systems

NOTE:

During testing, if DTCs other than DTC 11/B0102 are displayed, disregard them.

Diagnostic Procedure

1. Disable air bag system. See DISABLING SYSTEM under DISABLING & ACTIVATING AIR BAG SYSTEM. 2. Measure resistance between ground and Yellow/Black wire of spiral cable side of upper spiral cable connector. See WIRING DIAGRAMS . If resistance is more than one megohm, go to next step. If resistance is less than one megohm, go to step 5 . 3. Reconnect air bag sensor assembly connector C5 (center connector). Connect jumper wire between Yellow/Black wire and Yellow wire of spiral cable side of upper spiral cable connector. Connect negative battery cable. Wait at least 2 seconds. Turn ignition switch to ACC or ON position. Wait at least 20 seconds. Clear DTCs. See CLEARING CODES under DIAGNOSTICS. Turn ignition switch to LOCK position. Wait at least 20 seconds. Turn ignition switch to ACC or ON position. Wait at least 20 seconds. Retrieve codes. See RETRIEVING CODES under DIAGNOSTICS. If DTC 11/B0102 is displayed, replace air bag sensor assembly. If DTC 11/B0102 is not displayed, go to next step. 4. Turn ignition switch to LOCK position. Disconnect negative battery cable. Wait at least 90 seconds. Reconnect upper spiral cable connector (to driver-side air bag module). Reconnect negative battery cable. Wait at least 2 seconds. Turn ignition switch to ACC or ON position. Wait at least 20 seconds. Clear DTCs. See CLEARING CODES under DIAGNOSTICS. Turn ignition switch to LOCK position. Wait at least 20 seconds. Turn ignition switch to ACC or ON position. Wait at least 20 seconds. Retrieve codes. See RETRIEVING CODES under DIAGNOSTICS. If DTC 11/B0102 is displayed, replace driver-side air bag module. If DTC 11/B0102 is not displayed, system is functioning properly at this time. Check for intermittent fault. See AIR BAG WARNING LIGHT INTERMITTENT . 5. Disconnect lower spiral cable connector. Measure resistance between ground and Yellow/Black wire of spiral cable side of upper spiral cable connector. If resistance is more than one megohm, go to next step. If resistance is less than one megohm, replace spiral cable. 6. Measure resistance between ground and Yellow/Black wire of air bag sensor assembly side of lower spiral cable connector. If resistance is more than one megohm, system is functioning properly at this time. Check for intermittent fault. See AIR BAG WARNING LIGHT INTERMITTENT . If resistance is less than one megohm, replace wiring harness between spiral cable and air bag sensor assembly. DTC 12/B0103: DRIVER-SIDE AIR BAG SQUIB CIRCUIT SHORT TO BATTERY
Description

The driver-side air bag squib circuit consists of the air bag sensor assembly, spiral cable and driver-side air bag module. The squib causes driver-side air bag to deploy when all deployment conditions are satisfied.
Possible Causes

DTC 12/B0103 could be caused by a short to battery in squib circuit, squib malfunction, spiral cable malfunction or air bag sensor assembly malfunction. NOTE: During testing, if DTCs other than DTC 12/B0103 are displayed, disregard

2002 ACCESSORIES/SAFETY EQUIPMENT Toyota - Air Bag Restraint Systems

them.
Diagnostic Procedure

1. Disable air bag system. See DISABLING SYSTEM under DISABLING & ACTIVATING AIR BAG SYSTEM. Connect negative battery cable. 2. Measure voltage between ground and Yellow/Black wire of spiral cable side of upper spiral cable connector. See WIRING DIAGRAMS . If voltage is zero volt, go to next step. If voltage more than zero volt, go to step 5 . 3. Disconnect negative battery cable. Wait 90 seconds. Reconnect air bag sensor assembly connector C5 (center connector). Connect jumper wire between Yellow/Black wire and Yellow wire of spiral cable side of upper spiral cable connector. Connect negative battery cable. Wait at least 2 seconds. Turn ignition switch to ACC or ON position. Wait at least 20 seconds. Clear DTCs. See CLEARING CODES under DIAGNOSTICS. Turn ignition switch to LOCK position. Wait at least 20 seconds. Turn ignition switch to ACC or ON position. Wait at least 20 seconds. Retrieve codes. See RETRIEVING CODES under DIAGNOSTICS. If DTC 12/B0103 is displayed, replace air bag sensor assembly. If DTC 12/B0103 is not displayed, go to next step. 4. Turn ignition switch to LOCK position. Disconnect negative battery cable. Wait at least 90 seconds. Reconnect upper spiral cable connector (to driver-side air bag module). Reconnect negative battery cable. Wait at least 2 seconds. Turn ignition switch to ACC or ON position. Wait at least 20 seconds. Clear DTCs. See CLEARING CODES under DIAGNOSTICS. Turn ignition switch to LOCK position. Wait at least 20 seconds. Turn ignition switch to ACC or ON position. Wait at least 20 seconds. Retrieve codes. See RETRIEVING CODES under DIAGNOSTICS. If DTC 12/B0103 is displayed, replace driver-side air bag module. If DTC 12/B0103 is not displayed, system is functioning properly at this time. Check for intermittent fault. See AIR BAG WARNING LIGHT INTERMITTENT . 5. Disconnect lower spiral cable connector. Measure voltage between ground and Yellow/Black wire of spiral cable side of upper spiral cable connector. If voltage is zero volt, go to next step. If voltage is more than zero volt, replace spiral cable. 6. Measure voltage between ground and Yellow/Black wire of air bag sensor assembly side of lower spiral cable connector. If voltage is zero volt, system is functioning properly at this time. Check for intermittent fault. See AIR BAG WARNING LIGHT INTERMITTENT . If voltage is more than zero volt, replace wiring harness between spiral cable and air bag sensor assembly. DTC 13/B0100: SHORT IN DRIVER-SIDE AIR BAG MODULE SQUIB CIRCUIT
Description

The driver-side air bag squib circuit consists of the air bag sensor assembly, spiral cable and driver-side air bag module. The squib causes driver-side air bag to deploy when all deployment conditions are satisfied.
Possible Causes

DTC 13/B0100 could be caused by a short between D+ (Yellow/Black wire) and D- (Yellow wire) in squib circuit, squib malfunction, spiral cable malfunction or air bag sensor assembly malfunction. NOTE: During testing, if DTCs other than DTC 13/B0100 are displayed, disregard them.

2002 ACCESSORIES/SAFETY EQUIPMENT Toyota - Air Bag Restraint Systems

Diagnostic Procedure

1. Disable air bag system. See DISABLING SYSTEM under DISABLING & ACTIVATING AIR BAG SYSTEM. 2. Release shorting spring mechanism on air bag sensor assembly connector C5 (center connector). See RELEASING SHORTING SPRING under DIAGNOSTICS. Measure resistance between Yellow/Black wire and Yellow wire of spiral cable side of upper spiral cable connector. See WIRING DIAGRAMS . If resistance is less than one megohm, go to step 5 . If resistance is more than one megohm, go to next step. 3. Connect air bag sensor assembly connector C5. Connect jumper wire between Yellow/Black wire and Yellow wire of spiral cable side of upper spiral cable connector. Reconnect negative battery cable. Wait at least 2 seconds. Turn ignition switch to ACC or ON position. Wait at least 20 seconds. Clear DTCs. See CLEARING CODES under DIAGNOSTICS. Turn ignition switch to LOCK position. Wait at least 20 seconds. Turn ignition switch to ACC or ON position. Wait at least 20 seconds. Retrieve codes. See RETRIEVING CODES under DIAGNOSTICS. If DTC 13/B0100 is displayed, replace air bag sensor assembly. If DTC 13/B0100 is not displayed, go to next step. 4. Turn ignition switch to LOCK position. Disconnect negative battery cable. Wait at least 90 seconds. Reconnect upper spiral cable connector (to driver-side air bag module). Reconnect negative battery cable. Wait at least 2 seconds. Turn ignition switch to LOCK position. Wait at least 20 seconds. Turn ignition switch to ACC or ON position. Wait at least 20 seconds. Clear DTCs. See CLEARING CODES under DIAGNOSTICS. Turn ignition switch to LOCK position. Wait at least 20 seconds. Turn ignition switch to ACC or ON position. Wait at least 20 seconds. Retrieve codes. See RETRIEVING CODES under DIAGNOSTICS. If DTC 13/B0100 is displayed, replace driver-side air bag module. If DTC 13/B0100 is not displayed, the system is functioning properly at this time. Check for intermittent fault. See AIR BAG WARNING LIGHT INTERMITTENT . 5. Disconnect lower spiral cable connector. Release shorting spring on lower spiral cable connector. See RELEASING SHORTING SPRING under DIAGNOSTICS. Measure resistance between Yellow/Black wire and Yellow wire of spiral cable side of upper spiral cable connector. If resistance is less than one megohm, replace spiral cable. If resistance is more than one megohm, go to next step. 6. Release shorting spring on air bag sensor assembly connector C5. See RELEASING SHORTING SPRING under DIAGNOSTICS. Measure resistance between Yellow/Black wire and Yellow wire of air bag sensor assembly side of lower spiral cable connector. If resistance less than one megohm, repair or replace harness and connectors between air bag sensor assembly and spiral cable. If resistance is more than one megohm, system is functioning properly at this time. Check for intermittent fault. See AIR BAG WARNING LIGHT INTERMITTENT . DTC 14/B0101: OPEN IN DRIVER-SIDE AIR BAG MODULE SQUIB CIRCUIT
Description

The driver-side air bag squib circuit consists of the air bag sensor assembly, spiral cable and driver-side air bag module. The squib causes driver-side air bag to deploy when all deployment conditions are satisfied.
Possible Causes

DTC 14/B0101 could be caused by a open in D+ (Yellow/Black wire) or D- (Yellow wire) in squib circuit, squib malfunction, spiral cable malfunction or air bag sensor assembly malfunction. NOTE: During testing, if DTCs other than DTC 14/B0101 are displayed, disregard them.

2002 ACCESSORIES/SAFETY EQUIPMENT Toyota - Air Bag Restraint Systems

Diagnostic Procedure

1. Disable air bag system. See DISABLING SYSTEM under DISABLING & ACTIVATING AIR BAG SYSTEM. 2. Measure resistance between Yellow/Black wire and Yellow wire of spiral cable side of upper spiral cable connector. See WIRING DIAGRAMS . If resistance is more than one ohm, go to step 5 . If resistance is less than one ohm, go to next step. 3. Connect air bag sensor assembly connector C5 (center connector). Connect jumper wire between Yellow/Black wire and Yellow wire of spiral cable side of upper spiral cable connector. Connect negative battery cable. Wait at least 2 seconds. Turn ignition switch to ACC or ON position. Wait at least 20 seconds. Clear DTCs. See CLEARING CODES under DIAGNOSTICS. Turn ignition switch to LOCK position. Wait at least 20 seconds. Turn ignition switch to ACC or ON position. Wait at least 20 seconds. Retrieve codes. See RETRIEVING CODES under DIAGNOSTICS. If DTC 14/B0101 is displayed, replace air bag sensor assembly. If DTC 14/B0101 is not displayed, go to next step. 4. Turn ignition switch to LOCK position. Disconnect negative battery cable. Wait at least 90 seconds. Reconnect upper spiral cable connector (to driver-side air bag module). Reconnect negative battery cable. Wait at least 2 seconds. Turn ignition switch to ACC or ON position. Wait at least 20 seconds. Clear DTCs. See CLEARING CODES under DIAGNOSTICS. Turn ignition switch to LOCK position. Wait at least 20 seconds. Turn ignition switch to ACC or ON position. Wait at least 20 seconds. Retrieve codes. See RETRIEVING CODES under DIAGNOSTICS. If DTC 14/B0101 is displayed, replace driver-side air bag module. If DTC 14/B0101 is not displayed, the system is functioning properly at this time. Check for intermittent fault. See AIR BAG WARNING LIGHT INTERMITTENT . 5. Disconnect lower spiral cable connector. Measure resistance between Yellow/Black wire and Yellow wire of spiral cable side of upper spiral cable connector. If resistance is more than one ohm, replace spiral cable. If resistance is less than one ohm, go to next step. 6. Measure resistance between Yellow/Black wire and Yellow wire of air bag sensor assembly side of lower spiral cable connector. If resistance more than one ohm, repair or replace harness or connector between air bag sensor assembly and spiral cable. If resistance is less than one ohm, system is functioning properly at this time. Check for intermittent fault. See AIR BAG WARNING LIGHT INTERMITTENT . DTC 15/B1156 & B1157: RIGHT FRONT AIR BAG SENSOR MALFUNCTION
Description

The front air bag sensor circuit consists of the air bag sensor assembly and front air bag sensor.
Possible Causes

DTC 15/B1156 or B1157 could be caused by a front air bag sensor malfunction.
Diagnostic Procedure

1. Disable air bag system. See DISABLING SYSTEM under DISABLING & ACTIVATING AIR BAG SYSTEM. Leave right front air bag sensor connected. 2. Measure resistance between air bag sensor assembly connector C5, terminals No. 6 (circuit SR+, Black/White wire) and No. 5 (circuit SR-, Brown/White wire). See Fig. 16 . If resistance is 754-886 ohms, go to next step. If resistance is not 754-886 ohms, go to step 6 .

2002 ACCESSORIES/SAFETY EQUIPMENT Toyota - Air Bag Restraint Systems

3. Measure resistance between ground and air bag sensor assembly connector C5, terminal No. 6 (circuit SR+, Black/White wire). If resistance is more than one megohm, go to next step. If resistance is less than one megohm, go to step 9 . 4. Connect negative battery cable. Wait 2 seconds. Measure voltage between ground and air bag sensor assembly connector C5, terminal No. 6 (circuit SR+, Black/White wire). If voltage is less than one volt, go to next step. If voltage is more than one volt, go to step 11 . 5. Turn ignition switch to LOCK position. Disconnect negative battery cable. Wait at least 90 seconds. Connect right front air bag sensor and air bag sensor assembly connector C5. Connect negative battery cable. Wait at least 20 seconds. Turn ignition switch to ACC or ON position. Clear DTCs. See CLEARING CODES under DIAGNOSTICS. Turn ignition switch to LOCK position. Wait at least 20 seconds. Turn ignition switch to ACC or ON position. Wait at least 20 seconds. Retrieve codes. See RETRIEVING CODES under DIAGNOSTICS. If DTC 15/B1156 or B1157 is displayed, replace air bag sensor assembly. If DTC 15/B1156 or B1157 is not displayed, system is functioning properly at this time. Check for intermittent fault. See AIR BAG WARNING LIGHT INTERMITTENT under DIAGNOSTIC TESTS. 6. Disconnect right front air bag sensor connector. Measure resistance across sensor terminals. If resistance is 754-886 ohms, go to next step. If resistance is not 754-886 ohms, replace right front air bag sensor. 7. Disconnect right front air bag sensor Yellow 2-pin sub-harness connector. Connector is located under left side of instrument panel near junction block. Measure resistance between Black/White and Brown/White wires of right front air bag sensor harness connector (sensor connector). If resistance is less than one megohm, replace right front air bag sensor sub-harness between sensor and instrument panel connector. If resistance is more than one megohm, go to next step. 8. Connect jumper wire between Black/white and Brown/White wire of right front air bag sensor side of Yellow 2-pin instrument panel sub-harness connector. Measure resistance between Black/White and Brown/White wires of right front air bag sensor harness connector (sensor connector). If resistance is more than one ohm, replace right front air bag sensor sub-harness between sensor and instrument panel connector. If resistance is less than one ohm, repair or replace harness or connector between air bag sensor assembly and sub-harness. 9. Disconnect right front air bag sensor connector. Measure resistance between ground and air bag sensor assembly connector C5, terminals No. 6 (circuit SR+, Black/White wire) and No. 5 (circuit SR, Brown/White wire) independently. If resistance is less than one megohm, go to next step. If resistance is more than one megohm, replace right front air bag sensor. 10. Disconnect right front air bag sensor Yellow 2-pin sub-harness connector. Connector is located under left side of instrument panel near junction block. Measure resistance between Black/White and Brown/White wires of right front air bag sensor side of Yellow 2-pin sub-harness connector. If resistance is less than one megohm, replace right front air bag sensor sub-harness between sensor and instrument panel connector. If resistance is more than one megohm, repair or replace harness or connector between air bag sensor assembly and sub-harness. 11. Disconnect right front air bag sensor connector. Measure voltage between ground and air bag sensor assembly connector C5, terminals No. 6 (circuit SR+, Black/White wire) and No. 5 (circuit SR-, Brown/White wire) independently. If voltage is less than one volt, go to next step. If voltage is more than one volt, replace right front air bag sensor. 12. Disconnect right front air bag sensor Yellow 2-pin sub-harness connector. Connector is located under left side of instrument panel near junction block. Measure voltage between ground Black/White wire and Brown/White wire of right front air bag sensor side of Yellow 2-pin sub-harness connector independently. If voltage is more than one volt, replace right front air bag sensor sub-harness between sensor and instrument panel connector. If voltage is less than one volt, repair or replace harness or connector between air bag sensor assembly and sub-harness.

2002 ACCESSORIES/SAFETY EQUIPMENT Toyota - Air Bag Restraint Systems

DTC 16/B1158 & B1159: LEFT FRONT AIR BAG SENSOR MALFUNCTION
Description

The front air bag sensor circuit consists of the air bag sensor assembly and front air bag sensor.
Possible Causes

DTC 16/B1158 or B1159 could be caused by a front air bag sensor malfunction.
Diagnostic Procedure

1. Disable air bag system. See DISABLING SYSTEM under DISABLING & ACTIVATING AIR BAG SYSTEM. Leave left front air bag sensor connected. 2. Measure resistance between air bag sensor assembly connector C5, terminals No. 11 (circuit SL+, White/Red wire) and No. 12 (circuit SL-, Brown wire). See Fig. 16 . If resistance is 754-886 ohms, go to next step. If resistance is not 754-886 ohms, go to step 6 . 3. Measure resistance between ground and air bag sensor assembly connector C5, terminal No. 11 (circuit SL+, White/Red wire). If resistance is more than one megohm, go to next step. If resistance is less than one megohm, go to step 9 . 4. Connect negative battery cable. Wait 2 seconds. Measure voltage between ground and air bag sensor assembly connector C5, terminal No. 11 (circuit SL+, White/Red wire). If voltage is less than one volt, go to next step. If voltage is more than one volt, go to step 11 . 5. Turn ignition switch to LOCK position. Disconnect negative battery cable. Wait at least 90 seconds. Connect left front air bag sensor and air bag sensor assembly connector C5. Connect negative battery cable. Wait at least 20 seconds. Turn ignition switch to ACC or ON position. Clear DTCs. See CLEARING CODES under DIAGNOSTICS. Turn ignition switch to LOCK position. Wait at least 20 seconds. Turn ignition switch to ACC or ON position. Wait at least 20 seconds. Retrieve codes. See RETRIEVING CODES under DIAGNOSTICS. If DTC 16/B1158 or B1159 is displayed, replace left front air bag sensor. If DTC 16/B1158 or B1159 is not displayed, system is functioning properly at this time. Check for intermittent fault. See AIR BAG WARNING LIGHT INTERMITTENT under DIAGNOSTIC TESTS. 6. Disconnect left front air bag sensor connector. Measure resistance across sensor terminals. If resistance is 754-886 ohms, go to next step. If resistance is not 754-886 ohms, replace left front air bag sensor. 7. Disconnect left front air bag sensor Yellow 2-pin sub-harness connector. Connector is located under left side of instrument panel near junction block. Measure resistance between White/Red and Brown wires of left front air bag sensor harness connector (sensor connector). If resistance is less than one megohm, replace left front air bag sensor sub-harness between sensor and instrument panel connector. If resistance is more than one megohm, go to next step. 8. Connect jumper wire between White/Red and Brown wire of left front air bag sensor side of Yellow 2-pin instrument panel sub-harness connector. Measure resistance between White/Red and Brown wires of left front air bag sensor harness connector (sensor connector). If resistance is more than one ohm, replace left front air bag sensor sub-harness between sensor and instrument panel connector. If resistance is less than one ohm, repair or replace harness or connector between air bag sensor assembly and sub-harness. 9. Disconnect left front air bag sensor connector. Measure resistance between ground and air bag sensor assembly connector C5, terminals No. 11 (circuit SL+, White/Red wire) and No. 12 (circuit SL-, Brown wire) independently. If resistance is less than one megohm, go to next step. If resistance is

2002 ACCESSORIES/SAFETY EQUIPMENT Toyota - Air Bag Restraint Systems

more than one megohm, replace left front air bag sensor. 10. Disconnect left front air bag sensor Yellow 2-pin sub-harness connector. Connector is located under left side of instrument panel near junction block. Measure resistance between White/Red and Brown wires of left front air bag sensor side of Yellow 2-pin sub-harness connector. If resistance is less than one megohm, replace left front air bag sensor sub-harness between sensor and instrument panel connector. If resistance is more than one megohm, repair or replace harness or connector between air bag sensor assembly and sub-harness. 11. Disconnect left front air bag sensor connector. Measure voltage between ground and air bag sensor assembly connector C5, terminals No. 11 (circuit SL+, White/Red wire) and No. 12 (circuit SL-, Brown wire) independently. If voltage is less than one volt, go to next step. If voltage is more than one volt, replace left front air bag sensor. 12. Disconnect left front air bag sensor Yellow 2-pin sub-harness connector. Connector is located under left side of instrument panel near junction block. Measure voltage between ground and White/Red wire and Brown wire of left front air bag sensor side of Yellow 2-pin sub-harness connector independently. If voltage is more than one volt, replace left front air bag sensor sub-harness between sensor and instrument panel connector. If voltage is less than one volt, repair or replace harness or connector between air bag sensor assembly and sub-harness. DTC 31/B1100: AIR BAG SENSOR ASSEMBLY MALFUNCTION
Description

The air bag sensor assembly consists of an air bag sensor, safing sensor, drive circuit, diagnosis circuit and ignition control circuit. The air bag sensor assembly receives signals from air bag sensor, judges whether or not the air bag must be deployed and diagnosis system malfunction.
Possible Causes

DTC 31/B1100 could be caused by a air bag sensor assembly malfunction. NOTE: If a DTC other than DTC 31/B1100 is displayed at same time as DTC 31/B1100, repair fault indicated by DTC other than DTC 31/B1100 before using this procedure.

Diagnostic Procedure

1. Disable air bag system. See DISABLING SYSTEM under DISABLING & ACTIVATING AIR BAG SYSTEM. Reconnect negative battery cable. 2. Turn ignition switch to ON position. Measure voltage between ground and air bag sensor assembly connector C5 (center connector), terminals No. 3 (circuit IG2, Black/Orange wire) and No. 4 (circuit ACC, Gray wire) independently. See Fig. 16 . If voltage is more than 16 volts, check battery and charging system operation. If voltage is less than 16 volts, go to next step. 3. Clear DTCs. See CLEARING CODES under DIAGNOSTICS. Turn ignition switch to LOCK position. Wait at least 20 seconds. Turn ignition switch to ACC or ON position. Wait at least 20 seconds. Repeat at least 5 times. Retrieve DTCs. See RETRIEVING CODES under DIAGNOSTICS. If DTC 31/B1100 is displayed, replace air bag sensor assembly. If DTC 31/B1100 is not displayed, system is functioning properly at this time. Check for intermittent fault. See AIR BAG WARNING LIGHT INTERMITTENT . DTC 32/B1140: RIGHT-SIDE AIR BAG SENSOR ASSEMBLY MALFUNCTION

2002 ACCESSORIES/SAFETY EQUIPMENT Toyota - Air Bag Restraint Systems

Description

The side air bag sensor assembly consists of a safing sensor, diagnosis circuit and lateral deceleration sensor. The side air bag sensor assembly receives signals from lateral deceleration sensor, judges whether or not the air bag must be deployed and diagnosis system malfunction.
Possible Causes

DTC 32/B1140 could be caused by a right-side air bag sensor assembly malfunction. NOTE: During testing, if DTCs other than DTC 32/B1140 are displayed, disregard them.

Diagnostic Procedure

1. Turn ignition switch to ACC or On position. Wait at least 20 seconds. Clear DTCs. See CLEARING CODES under DIAGNOSTICS. Turn ignition switch to LOCK position. Wait at least 20 seconds. Turn ignition switch to ACC or ON position. Wait at least 20 seconds. Retrieve DTCs. See RETRIEVING CODES under DIAGNOSTICS. If DTC 32/B1140 is not displayed, go to step 8 . If DTC 32/B1140 is displayed, go to next step. 2. Access right-side air bag sensor assembly. See SIDE AIR BAG SENSOR ASSEMBLY under REMOVAL & INSTALLATION. Ensure right-side air bag sensor assembly harness connector is properly connected and secure. Reconnect if necessary. Go to next step. 3. Disable air bag system. See DISABLING SYSTEM under DISABLING & ACTIVATING AIR BAG SYSTEM. 4. Disconnect right-side air bag sensor assembly connector. Connect jumper wire between right-side air bag sensor assembly harness connector terminals No. 2 (circuit SSR+, Blue/Yellow wire) and No. 4 (circuit ESR, Gray wire). See WIRING DIAGRAMS . Measure resistance between air bag sensor assembly connector C6, terminals No. 10 (circuit SSR+, Blue/Yellow wire) and No. 7 (circuit ESR, Gray wire). See Fig. 16 . If resistance is less than one ohm, go to next step. If resistance is more than one ohm, repair or replace harness or connector between right-side air bag sensor assembly and air bag sensor assembly. 5. Connect jumper wire between right-side air bag sensor assembly harness connector terminals No. 1 (circuit VUPR, Pink wire) and No. 3 (circuit FSR, Light Green wire). See WIRING DIAGRAMS . Measure resistance between air bag sensor assembly connector C6, terminals No. 12 (circuit VUPR, Pink wire) and No. 9 (circuit FSR, Light Green wire). See Fig. 16 . If resistance is less than one ohm, remove jumper wire and go to next step. If resistance is more than one ohm, repair or replace harness or connector between right-side air bag sensor assembly and air bag sensor assembly. 6. Measure resistance between ground and air bag sensor assembly harness connector C6, terminals No. 12 (circuit VUPR, Pink wire), No. 10 (circuit SSR+, Blue/Yellow wire) and No. 9 (circuit FSR, Light Green wire) individually. See Fig. 16 . If resistance is more than one megohm, go to next step. If resistance is less than one megohm, repair or replace harness or connector between right-side air bag sensor assembly and air bag sensor assembly. 7. Connect negative battery cable. Turn ignition switch to ACC or ON position. Measure voltage between ground and air bag sensor assembly harness connector C6, terminals No. 12 (circuit VUPR, Pink wire), No. 10 (circuit SSR+, Blue/Yellow wire), No. 9 (circuit FSR, Light Green wire) and No. 7 (circuit ERS, Gray wire) individually. See Fig. 16 . If voltage is zero volt, turn ignition switch to LOCK position, disconnect negative battery cable and go to next step. If voltage is more than zero volt, repair or replace harness or connector between right-side air bag sensor assembly and air bag

2002 ACCESSORIES/SAFETY EQUIPMENT Toyota - Air Bag Restraint Systems

sensor assembly. See WIRING DIAGRAMS . 8. Ensure negative battery cable is disconnected. Reconnect all system components. Connect negative battery cable. Wait at least 2 seconds. Turn ignition switch to ACC or ON position. Wait at least 20 seconds. Clear DTCs. See CLEARING CODES under DIAGNOSTICS. Turn ignition switch to LOCK position. Wait at least 20 seconds. Turn ignition switch to ACC or ON position. Wait at least 20 seconds. Retrieve DTCs. See RETRIEVING CODES under DIAGNOSTICS. If DTC 32/B1140 is not displayed, system is functioning properly at this time. Check for intermittent fault. See AIR BAG WARNING LIGHT INTERMITTENT . If DTC 32/B1140 is displayed, replace right-side air bag sensor assembly. DTC 33/B1141: LEFT-SIDE AIR BAG SENSOR ASSEMBLY MALFUNCTION
Description

The side air bag sensor assembly consists of a safing sensor, diagnosis circuit and lateral deceleration sensor. The side air bag sensor assembly receives signals from lateral deceleration sensor, judges whether or not the air bag must be deployed and diagnosis system malfunction.
Possible Causes

DTC 33/B1141 could be caused by a left-side air bag sensor assembly malfunction. NOTE: During testing, if DTCs other than DTC 33/B1141 are displayed, disregard them.

Diagnostic Procedure

1. Turn ignition switch to ACC or On position. Wait at least 20 seconds. Clear DTCs. See CLEARING CODES under DIAGNOSTICS. Turn ignition switch to LOCK position. Wait at least 20 seconds. Turn ignition switch to ACC or ON position. Wait at least 20 seconds. Retrieve DTCs. See RETRIEVING CODES under DIAGNOSTICS. If DTC 33/B1141 is not displayed, go to step 8 . If DTC 33/B1141 is displayed, go to next step. 2. Access left-side air bag sensor assembly. See SIDE AIR BAG SENSOR ASSEMBLY under REMOVAL & INSTALLATION. Ensure left-side air bag sensor assembly harness connector is properly connected and secure. Reconnect if necessary. Go to next step. 3. Disable air bag system. See DISABLING SYSTEM under DISABLING & ACTIVATING AIR BAG SYSTEM. 4. Disconnect left-side air bag sensor assembly connector. Connect jumper wire between left-side air bag sensor assembly harness connector terminals No. 2 (circuit SSL+, Blue/White wire) and No. 4 (circuit ESL, Gray/Blue wire). See WIRING DIAGRAMS . Measure resistance between air bag sensor assembly connector C4, terminals No. 9 (circuit SSL+, Blue/White wire) and No. 12 (circuit ESL, Gray/Blue wire). See Fig. 16 . If resistance is less than one ohm, go to next step. If resistance is more than one ohm, repair or replace harness or connector between left-side air bag sensor assembly and air bag sensor assembly. 5. Connect jumper wire between left-side air bag sensor assembly harness connector terminals No. 7 (circuit VUPL, Pink/Blue wire) and No. 10 (circuit FSL, Light Green/Black wire). See WIRING DIAGRAMS . Measure resistance between air bag sensor assembly connector C4, terminals No. 7 (circuit VUPL, Pink/Blue wire) and 10 (circuit FSL, Light Green/Black wire). See Fig. 16 . If resistance is less than one ohm, go to next step. If resistance is more than one ohm, repair or replace harness or connector between left-side air bag sensor assembly and air bag sensor assembly.

2002 ACCESSORIES/SAFETY EQUIPMENT Toyota - Air Bag Restraint Systems

6. Measure resistance between ground and air bag sensor assembly harness connector C4, terminals No. 7 (circuit VUPL, Pink/Blue wire), No. 9 (circuit SSL+, Blue/White wire) and No. 10 (circuit FSL, Light Green/Black wire) individually. See Fig. 16 . If resistance is more than one megohm, go to next step. If resistance is less than one megohm, repair or replace harness or connector between left-side air bag sensor assembly and air bag sensor assembly. See WIRING DIAGRAMS . 7. Connect negative battery cable. Turn ignition switch to ACC or ON position. Measure voltage between ground and air bag sensor assembly harness connector C4, terminals No. 7 (circuit VUPL, Pink/Blue wire), No. 9 (circuit SSL+, Blue/White wire), No. 10 (circuit FSL, Light Green/Black wire) and No. 12 (circuit ESL, Gray/Blue wire) individually. See Fig. 16 . If voltage is zero volt, turn ignition switch to LOCK position, disconnect negative battery cable and go to next step. If voltage is more than zero volt, repair or replace harness or connector between left-side air bag sensor assembly and air bag sensor assembly. See WIRING DIAGRAMS . 8. Ensure negative battery cable is disconnected. Reconnect all system components. Connect negative battery cable. Wait at least 2 seconds. Turn ignition switch to ACC or ON position. Wait at least 20 seconds. Clear DTCs. See CLEARING CODES under DIAGNOSTICS. Turn ignition switch to LOCK position. Wait at least 20 seconds. Turn ignition switch to ACC or ON position. Wait at least 20 seconds. Retrieve DTCs. See RETRIEVING CODES under DIAGNOSTICS. If DTC 33/B1141 is not displayed, system is functioning properly at this time. Check for intermittent fault. See AIR BAG WARNING LIGHT INTERMITTENT . If DTC 33/B1141 is displayed, replace left-side air bag sensor assembly. DTC 41/B0112: SHORT TO GROUND IN RIGHT-SIDE AIR BAG MODULE SQUIB CIRCUIT
Description

The side air bag module squib circuit consists of the air bag sensor assembly and side air bag module. The squib circuit causes the side air bag to deploy when deployment conditions are satisfied.
Possible Causes

DTC 41/B0112 could be caused by a short to ground in side air bag squib circuit, side air bag squib malfunction or air bag sensor assembly malfunction. NOTE: During testing, if DTCs other than DTC 41/B0112 are displayed, disregard them.

Diagnostic Procedure

1. Disable air bag system. See DISABLING SYSTEM under DISABLING & ACTIVATING AIR BAG SYSTEM. Ensure right-side air bag module and air bag sensor assembly are disconnected. 2. Measure resistance between ground and right-side air bag module harness connector Yellow/Red wire. See WIRING DIAGRAMS . If resistance is more than one megohm, go to next step. If resistance is less than one megohm, repair or replace harness or connector between right-side air bag module and air bag sensor assembly. 3. Reconnect air bag sensor assembly connector C6 (right connector). Connect jumper wire between air bag sensor assembly side of right-side air bag module harness connector Yellow/Red wire (circuit FR+) and Yellow/Green wire (circuit FR-). See WIRING DIAGRAMS . Connect negative battery cable. Wait at least 2 seconds. Turn ignition switch to ACC or ON position. Wait at least 20 seconds. Clear DTCs. See CLEARING CODES under DIAGNOSTICS. Turn ignition switch to LOCK position. Wait at least 20 seconds. Turn ignition switch to ACC or ON position. Wait at least 20

2002 ACCESSORIES/SAFETY EQUIPMENT Toyota - Air Bag Restraint Systems

seconds. Retrieve DTCs. See RETRIEVING CODES under DIAGNOSTICS. If DTC 41/B0112 is not displayed, go to next step. If DTC 41/B0112 is displayed, replace air bag sensor assembly. 4. Turn ignition switch to LOCK position. Disconnect negative battery cable. Wait at least 90 seconds. Reconnect right-side air bag module connector. Connect negative battery cable. Wait at least 2 seconds. Turn ignition switch to ACC or ON position. Wait at least 20 seconds. Clear DTCs. See CLEARING CODES under DIAGNOSTICS. Turn ignition switch to LOCK position. Wait at least 20 seconds. Turn ignition switch to ACC or ON position. Wait at least 20 seconds. Retrieve DTCs. See RETRIEVING CODES under DIAGNOSTICS. If DTC 41/B0112 is not displayed, system is functioning properly at this time. Check for intermittent fault. See AIR BAG WARNING LIGHT INTERMITTENT . If DTC 41/B0112 is displayed, replace right-side air bag module. DTC 42/B0113: SHORT TO BATTERY IN RIGHT-SIDE AIR BAG MODULE SQUIB CIRCUIT
Description

The side air bag module squib circuit consists of the air bag sensor assembly and side air bag module. The squib circuit causes the side air bag to deploy when deployment conditions are satisfied.
Possible Causes

DTC 42/B0113 could be caused by a short to battery in side air bag squib circuit, side air bag squib malfunction or air bag sensor assembly malfunction. NOTE: During testing, if DTCs other than DTC 42/B0113 are displayed, disregard them.

Diagnostic Procedure

1. Disable air bag system. See DISABLING SYSTEM under DISABLING & ACTIVATING AIR BAG SYSTEM. Reconnect negative battery cable. 2. Measure voltage between ground and right-side air bag module harness connector Yellow/Red wire. See WIRING DIAGRAMS . If voltage is zero volt, go to next step. If voltage is not zero volt, repair or replace harness or connector between right-side air bag module and air bag sensor assembly. 3. Disconnect negative battery cable. Wait at least 90 seconds. Reconnect air bag sensor assembly connector C6 (right connector). Connect jumper wire between air bag sensor assembly side of rightside air bag module harness connector Yellow/Red wire (circuit FR+) and Yellow/Green wire (circuit FR-). Connect negative battery cable. Wait at least 2 seconds. Turn ignition switch to ACC or ON position. Wait at least 20 seconds. Clear DTCs. See CLEARING CODES under DIAGNOSTICS. Turn ignition switch to LOCK position. Wait at least 20 seconds. Turn ignition switch to ACC or ON position. Wait at least 20 seconds. Retrieve DTCs. See RETRIEVING CODES under DIAGNOSTICS. If DTC 42/B0113 is not displayed, go to next step. If DTC 42/B0113 is displayed, replace air bag sensor assembly. 4. Turn ignition switch to LOCK position. Disconnect negative battery cable. Wait at least 90 seconds. Reconnect right-side air bag module connector. Connect negative battery cable. Wait at least 2 seconds. Turn ignition switch to ACC or ON position. Wait at least 20 seconds. Clear DTCs. See CLEARING CODES under DIAGNOSTICS. Turn ignition switch to LOCK position. Wait at least 20 seconds. Turn ignition switch to ACC or ON position. Wait at least 20 seconds. Retrieve DTCs. See RETRIEVING CODES under DIAGNOSTICS. If DTC 42/B0113 is not displayed, system is functioning properly at this time. Check for intermittent fault. See AIR BAG WARNING LIGHT INTERMITTENT . If DTC 42/B0113 is displayed, replace side air bag module.

2002 ACCESSORIES/SAFETY EQUIPMENT Toyota - Air Bag Restraint Systems

DTC 43/B0110: SHORT IN RIGHT-SIDE AIR BAG MODULE SQUIB CIRCUIT

Description

The side air bag module squib circuit consists of the air bag sensor assembly and side air bag module. The squib circuit causes the side air bag to deploy when deployment conditions are satisfied.
Possible Causes

DTC 43/B0110 could be caused by a short between Yellow/Red (circuit FR+) and Yellow/Green (circuit FR-) wires in side air bag squib circuit, side air bag squib malfunction or air bag sensor assembly malfunction. NOTE: During testing, if DTCs other than DTC 43/B0110 are displayed, disregard them.

Diagnostic Procedure

1. Disable air bag system. See DISABLING SYSTEM under DISABLING & ACTIVATING AIR BAG SYSTEM. 2. Release shorting spring on air bag sensor assembly connector C6. See RELEASING SHORTING SPRING under DIAGNOSTICS. Measure resistance between air bag sensor assembly side of rightside air bag module harness connector Yellow/Red wire (circuit FR+) and Yellow/Green wire (circuit FR-). See WIRING DIAGRAMS . If resistance is more than one megohm, go to next step. If resistance is less than one megohm, repair or replace harness or connector between right-side air bag module and air bag sensor assembly. 3. Reconnect air bag sensor assembly connector C6 (right connector) to air bag sensor assembly. Connect jumper wire between air bag sensor assembly side of right-side air bag module harness connector Yellow/Red wire (circuit FR+) and Yellow/Green wire (circuit FR-). Connect negative battery cable. Wait at least 2 seconds. Turn ignition switch to ACC or ON position. Wait at least 20 seconds. Clear DTCs. See CLEARING CODES under DIAGNOSTICS. Turn ignition switch to LOCK position. Wait at least 20 seconds. Turn ignition switch to ACC or ON position. Wait at least 20 seconds. Retrieve DTCs. See RETRIEVING CODES under DIAGNOSTICS. If DTC 43/B0110 is not displayed, go to next step. If DTC 43/B0110 is displayed, replace air bag sensor assembly. 4. Turn ignition switch to LOCK position. Disconnect negative battery cable. Wait at least 90 seconds. Reconnect right-side air bag module connector. Connect negative battery cable. Wait at least 2 seconds. Turn ignition switch to ACC or ON position. Wait at least 20 seconds. Clear DTCs. See CLEARING CODES under DIAGNOSTICS. Turn ignition switch to LOCK position. Wait at least 20 seconds. Turn ignition switch to ACC or ON position. Wait at least 20 seconds. Retrieve DTCs. See RETRIEVING CODES under DIAGNOSTICS. If DTC 43/B0110 is not displayed, system is functioning properly at this time. Check for intermittent fault. See AIR BAG WARNING LIGHT INTERMITTENT . If DTC 43/B0110 is displayed, replace right-side air bag module. DTC 44/B0111: OPEN IN RIGHT-SIDE AIR BAG MODULE SQUIB CIRCUIT
Description

The side air bag module squib circuit consists of the air bag sensor assembly and side air bag module. The squib circuit causes the side air bag to deploy when deployment conditions are satisfied.

2002 ACCESSORIES/SAFETY EQUIPMENT Toyota - Air Bag Restraint Systems

Possible Causes

DTC 44/B0111 could be caused by a open in Yellow/Red (circuit FR+) and Yellow/Green (circuit FR-) wires in side air bag squib circuit, side air bag squib malfunction or air bag sensor assembly malfunction. NOTE: During testing, if DTCs other than DTC 44/B0111 are displayed, disregard them.

Diagnostic Procedure

1. Disable air bag system. See DISABLING SYSTEM under DISABLING & ACTIVATING AIR BAG SYSTEM. 2. Measure resistance between air bag sensor assembly side of right-side air bag module harness connector Yellow/Red wire (circuit FR+) and Yellow/Green wire (circuit FR-). See WIRING DIAGRAMS . If resistance is less than one ohm, go to next step. If resistance is more than one ohm, repair or replace harness or connector between right-side air bag module and air bag sensor assembly. 3. Reconnect air bag sensor assembly connector C6 (right connector) to air bag sensor assembly. Connect jumper wire between right-side air bag module harness connector Yellow/Red wire (circuit FR+) and Yellow/Green wire (circuit FR-). Connect negative battery cable. Wait at least 2 seconds. Turn ignition switch to ACC or ON position. Wait at least 20 seconds. Clear DTCs. See CLEARING CODES under DIAGNOSTICS. Turn ignition switch to LOCK position. Wait at least 20 seconds. Turn ignition switch to ACC or ON position. Wait at least 20 seconds. Retrieve DTCs. See RETRIEVING CODES under DIAGNOSTICS. If DTC 44/B0111 is not displayed, go to next step. If DTC 44/B0111 is displayed, replace air bag sensor assembly. 4. Turn ignition switch to LOCK position. Disconnect negative battery cable. Wait at least 90 seconds. Reconnect right-side air bag module connector. Connect negative battery cable. Wait at least 2 seconds. Turn ignition switch to ACC or ON position. Wait at least 20 seconds. Clear DTCs. See CLEARING CODES under DIAGNOSTICS. Turn ignition switch to LOCK position. Wait at least 20 seconds. Turn ignition switch to ACC or ON position. Wait at least 20 seconds. Retrieve DTCs. See RETRIEVING CODES under DIAGNOSTICS. If DTC 44/B0111 is not displayed, system is functioning properly at this time. Check for intermittent fault. See AIR BAG WARNING LIGHT INTERMITTENT . If DTC 44/B0111 is displayed, replace side air bag module. DTC 45/B0117: SHORT TO GROUND IN LEFT-SIDE AIR BAG MODULE SQUIB CIRCUIT
Description

The side air bag module squib circuit consists of the air bag sensor assembly and side air bag module. The squib circuit causes the side air bag to deploy when deployment conditions are satisfied.
Possible Causes

DTC 45/B0117 could be caused by a short to ground in side air bag squib circuit, side air bag squib malfunction or air bag sensor assembly malfunction. NOTE: During testing, if DTCs other than DTC 45/B0117 are displayed, disregard them.

Diagnostic Procedure

2002 ACCESSORIES/SAFETY EQUIPMENT Toyota - Air Bag Restraint Systems

1. Disable air bag system. See DISABLING SYSTEM under DISABLING & ACTIVATING AIR BAG SYSTEM. 2. Release shorting spring on air bag sensor assembly connector C4. See RELEASING SHORTING SPRING under DIAGNOSTICS. Measure resistance between ground and air bag sensor assembly side of left-side air bag module harness connector Yellow/Red wire and Yellow/Green wire. If resistance is more than one megohm, go to next step. If resistance is less than one megohm, repair or replace harness or connector between left-side air bag module and air bag sensor assembly. 3. Reconnect air bag sensor assembly connector C4 (left connector) to air bag sensor assembly. Connect jumper wire between left-side air bag module harness connector Yellow/Red wire (circuit FL+) and Yellow/Green wire (circuit FL-). Connect negative battery cable. Wait at least 2 seconds. Turn ignition switch to ACC or ON position. Wait at least 20 seconds. Clear DTCs. See CLEARING CODES under DIAGNOSTICS. Turn ignition switch to LOCK position. Wait at least 20 seconds. Turn ignition switch to ACC or ON position. Wait at least 20 seconds. Retrieve DTCs. See RETRIEVING CODES under DIAGNOSTICS. If DTC 45/B0117 is not displayed, go to next step. If DTC 45/B0117 is displayed, replace air bag sensor assembly. 4. Turn ignition switch to LOCK position. Disconnect negative battery cable. Wait at least 90 seconds. Reconnect left-side air bag module connector. Connect negative battery cable. Wait at least 2 seconds. Turn ignition switch to ACC or ON position. Wait at least 20 seconds. Clear DTCs. See CLEARING CODES under DIAGNOSTICS. Turn ignition switch to LOCK position. Wait at least 20 seconds. Turn ignition switch to ACC or ON position. Wait at least 20 seconds. Retrieve DTCs. See RETRIEVING CODES under DIAGNOSTICS. If DTC 45/B0117 is not displayed, system is functioning properly at this time. Check for intermittent fault. See AIR BAG WARNING LIGHT INTERMITTENT . If DTC 45/B0117 is displayed, replace left-side air bag module. DTC 46/B0118: SHORT TO BATTERY IN LEFT-SIDE AIR BAG MODULE SQUIB CIRCUIT
Description

The side air bag module squib circuit consists of the air bag sensor assembly and side air bag module. The squib circuit causes the side air bag to deploy when deployment conditions are satisfied.
Possible Causes

DTC 46/B0118 could be caused by a short to battery in side air bag squib circuit, side air bag squib malfunction or air bag sensor assembly malfunction. NOTE: During testing, if DTCs other than DTC 46/B0118 are displayed, disregard them.

Diagnostic Procedure

1. Disable air bag system. See DISABLING SYSTEM under DISABLING & ACTIVATING AIR BAG SYSTEM. Reconnect negative battery cable. 2. Turn ignition switch to ACC or ON position. Measure voltage between ground and Yellow/Red wire (circuit FL+) of air bag sensor assembly side of left-side air bag module harness connector. If voltage is zero volt, go to next step. If voltage is not zero volt, repair or replace harness or connector between left-side air bag module and air bag sensor assembly. 3. Disconnect negative battery cable. Wait at least 90 seconds. Reconnect air bag sensor assembly connector C4 (left connector) to air bag sensor assembly. Connect jumper wire between left-side air

2002 ACCESSORIES/SAFETY EQUIPMENT Toyota - Air Bag Restraint Systems

bag module harness connector Yellow/Red wire (circuit FL+) and Yellow/Green wire (circuit FL-). Connect negative battery cable. Wait at least 2 seconds. Turn ignition switch to ACC or ON position. Wait at least 20 seconds. Clear DTCs. See CLEARING CODES under DIAGNOSTICS. Turn ignition switch to LOCK position. Wait at least 20 seconds. Turn ignition switch to ACC or ON position. Wait at least 20 seconds. Retrieve DTCs. See RETRIEVING CODES under DIAGNOSTICS. If DTC 46/B0118 is not displayed, go to next step. If DTC 46/B0118 is displayed, replace air bag sensor assembly. 4. Turn ignition switch to LOCK position. Disconnect negative battery cable. Wait at least 90 seconds. Reconnect left-side air bag module connector. Connect negative battery cable. Wait at least 2 seconds. Turn ignition switch to ACC or ON position. Wait at least 20 seconds. Clear DTCs. See CLEARING CODES under DIAGNOSTICS. Turn ignition switch to LOCK position. Wait at least 20 seconds. Turn ignition switch to ACC or ON position. Wait at least 20 seconds. Retrieve DTCs. See RETRIEVING CODES under DIAGNOSTICS. If DTC 46/B0118 is not displayed, system is functioning properly at this time. Check for intermittent fault. See AIR BAG WARNING LIGHT INTERMITTENT . If DTC 46/B0118 is displayed, replace left-side air bag module. DTC 47/B0115: SHORT IN LEFT-SIDE AIR BAG MODULE SQUIB CIRCUIT
Description

The side air bag module squib circuit consists of the air bag sensor assembly and side air bag module. The squib circuit causes the side air bag to deploy when deployment conditions are satisfied.
Possible Causes

DTC 47/B0115 could be caused by a short between Yellow/Red (circuit FL+) and Yellow/Green (circuit FL-) wires in side air bag squib circuit, side air bag squib malfunction or air bag sensor assembly malfunction. NOTE: During testing, if DTCs other than DTC 47/B0115 are displayed, disregard them.

Diagnostic Procedure

1. Disable air bag system. See DISABLING SYSTEM under DISABLING & ACTIVATING AIR BAG SYSTEM. 2. Release shorting spring on air bag sensor assembly connector C4. See RELEASING SHORTING SPRING under DIAGNOSTICS. Measure resistance between Yellow/Red wire (circuit FL+) and Yellow/Green wire (circuit FL-) of air bag sensor assembly side of left-side air bag module harness connector. If resistance is more than one megohm, go to next step. If resistance is less than one megohm, repair or replace harness or connector between left-side air bag module and air bag sensor assembly. 3. Reconnect air bag sensor assembly connector C4 (left connector) to air bag sensor assembly. Connect jumper wire between left-side air bag module harness connector Yellow/Red wire (circuit FL+) and Yellow/Green wire (circuit FL-). Connect negative battery cable. Wait at least 2 seconds. Turn ignition switch to ACC or ON position. Wait at least 20 seconds. Clear DTCs. See CLEARING CODES under DIAGNOSTICS. Turn ignition switch to LOCK position. Wait at least 20 seconds. Turn ignition switch to ACC or ON position. Wait at least 20 seconds. Retrieve DTCs. See RETRIEVING CODES under DIAGNOSTICS. If DTC 47/B0115 is not displayed, go to next step. If DTC 47/B0115 is displayed, replace air bag sensor assembly.

2002 ACCESSORIES/SAFETY EQUIPMENT Toyota - Air Bag Restraint Systems

4. Turn ignition switch to LOCK position. Disconnect negative battery cable. Wait at least 90 seconds. Reconnect left-side air bag module connector. Connect negative battery cable. Wait at least 2 seconds. Turn ignition switch to ACC or ON position. Wait at least 20 seconds. Clear DTCs. See CLEARING CODES under DIAGNOSTICS. Turn ignition switch to LOCK position. Wait at least 20 seconds. Turn ignition switch to ACC or ON position. Wait at least 20 seconds. Retrieve DTCs. See RETRIEVING CODES under DIAGNOSTICS. If DTC 47/B0115 is not displayed, system is functioning properly at this time. Check for intermittent fault. See AIR BAG WARNING LIGHT INTERMITTENT . If DTC 47/B0115 is displayed, replace left-side air bag module. DTC 48/B0116: OPEN IN LEFT-SIDE AIR BAG MODULE SQUIB CIRCUIT
Description

The side air bag module squib circuit consists of the air bag sensor assembly and side air bag module. The squib circuit causes the side air bag to deploy when deployment conditions are satisfied.
Possible Causes

DTC 48/B0116 could be caused by a open in Yellow/Red (circuit FL+) and Yellow/Green (circuit FL-) wires in side air bag squib circuit, side air bag squib malfunction or air bag sensor assembly malfunction. NOTE: During testing, if DTCs other than DTC 48/B0116 are displayed, disregard them.

Diagnostic Procedure

1. Disable air bag system. See DISABLING SYSTEM under DISABLING & ACTIVATING AIR BAG SYSTEM. 2. Measure resistance between left-side air bag module harness connector Yellow/Red wire (circuit FL+) and Yellow/Green wire (circuit FL-). See WIRING DIAGRAMS . If resistance is less than one ohm, go to next step. If resistance is more than one ohm, repair or replace harness or connector between left-side air bag module and air bag sensor assembly. 3. Reconnect air bag sensor assembly connector C4 (left connector) to air bag sensor assembly. Connect jumper wire between left-side air bag module harness connector Yellow/Red wire (circuit FL+) and Yellow/Green wire (circuit FL-). Connect negative battery cable. Wait at least 2 seconds. Turn ignition switch to ACC or ON position. Wait at least 20 seconds. Clear DTCs. See CLEARING CODES under DIAGNOSTICS. Turn ignition switch to LOCK position. Wait at least 20 seconds. Turn ignition switch to ACC or ON position. Wait at least 20 seconds. Retrieve DTCs. See RETRIEVING CODES under DIAGNOSTICS. If DTC 48/B0116 is not displayed, go to next step. If DTC 48/B0116 is displayed, replace air bag sensor assembly. 4. Turn ignition switch to LOCK position. Disconnect negative battery cable. Wait at least 90 seconds. Reconnect left-side air bag module connector. Connect negative battery cable. Wait at least 2 seconds. Turn ignition switch to ACC or ON position. Wait at least 20 seconds. Clear DTCs. See CLEARING CODES under DIAGNOSTICS. Turn ignition switch to LOCK position. Wait at least 20 seconds. Turn ignition switch to ACC or ON position. Wait at least 20 seconds. Retrieve DTCs. See RETRIEVING CODES under DIAGNOSTICS. If DTC 48/B0116 is not displayed, system is functioning properly at this time. Check for intermittent fault. See AIR BAG WARNING LIGHT INTERMITTENT . If DTC 48/B0116 is displayed, replace left-side air bag module. DTC 51/B0107: SHORT TO GROUND IN PASSENGER-SIDE AIR BAG SQUIB CIRCUIT

2002 ACCESSORIES/SAFETY EQUIPMENT Toyota - Air Bag Restraint Systems

Description

The passenger-side air bag squib circuit consists of the air bag sensor assembly and passenger-side air bag module. The squib circuit causes the passenger-side air bag to deploy when deployment conditions are satisfied.
Possible Causes

DTC 51/B0107 could be caused by a short to ground in Yellow/Red (circuit P+) and Yellow/Green (circuit P-) wires in passenger-side air bag squib circuit, passenger-side air bag squib malfunction or air bag sensor assembly malfunction. NOTE: During testing, if DTCs other than DTC 51/B0107 are displayed, disregard them.

Diagnostic Procedure

1. Disable air bag system. See DISABLING SYSTEM under DISABLING & ACTIVATING AIR BAG SYSTEM. 2. Measure resistance between ground and Yellow/Red wire (circuit P+) of air bag sensor assembly side of passenger-side air bag module harness connector. See WIRING DIAGRAMS . If resistance is less than one megohm, repair or replace harness or connector between passenger-side air bag module and air bag sensor assembly. If resistance is more than one megohm, go to next step. 3. Reconnect air bag sensor assembly connector C5 (center connector) to air bag sensor assembly. Connect jumper wire between Yellow/Red wire (circuit P+) and Yellow/Green wire (circuit P-) of air bag sensor assembly side of passenger-side air bag module harness connector. Connect negative battery cable. Wait at least 2 seconds. Turn ignition switch to ACC or ON position. Wait at least 20 seconds. Clear DTCs. See CLEARING CODES under DIAGNOSTICS. Turn ignition switch to LOCK position. Wait at least 20 seconds. Turn ignition switch to ACC or ON position. Wait at least 20 seconds. Retrieve DTCs. See RETRIEVING CODES under DIAGNOSTICS. If DTC 51/B0107 is not displayed, go to next step. If DTC 51/B0107 is displayed, replace air bag sensor assembly. 4. Turn ignition switch to LOCK position. Disconnect negative battery cable. Wait at least 90 seconds. Reconnect passenger-side air bag module harness connector. Connect negative battery cable. Wait at least 2 seconds. Turn ignition switch to ACC or ON position. Wait at least 20 seconds. Clear DTCs. See CLEARING CODES under DIAGNOSTICS. Turn ignition switch to LOCK position. Wait at least 20 seconds. Turn ignition switch to ACC or ON position. Wait at least 20 seconds. Retrieve DTCs. See RETRIEVING CODES under DIAGNOSTICS. If DTC 51/B0107 is not displayed, system is functioning properly at this time. Check for intermittent fault. See AIR BAG WARNING LIGHT INTERMITTENT . If DTC 51/B0107 is displayed, replace passenger-side air bag module. DTC 52/B0108: SHORT TO BATTERY IN PASSENGER-SIDE AIR BAG SQUIB CIRCUIT
Description

The passenger-side air bag squib circuit consists of the air bag sensor assembly and passenger-side air bag module. The squib circuit causes the passenger-side air bag to deploy when deployment conditions are satisfied.
Possible Causes

2002 ACCESSORIES/SAFETY EQUIPMENT Toyota - Air Bag Restraint Systems

DTC 52/B0108 could be caused by a short to battery in Yellow/Red (circuit P+) and Yellow/Green (circuit P-) wires in passenger-side air bag squib circuit, passenger-side air bag squib malfunction or air bag sensor assembly malfunction. NOTE: During testing, if DTCs other than DTC 52/B0108 are displayed, disregard them.

Diagnostic Procedure

1. Disable air bag system. See DISABLING SYSTEM under DISABLING & ACTIVATING AIR BAG SYSTEM. Reconnect negative battery cable. 2. Turn ignition switch to ON position. Measure voltage between ground and Yellow/Red wire (circuit P+) of air bag sensor assembly side of passenger-side air bag module harness connector. See WIRING DIAGRAMS . If voltage is zero volt, go to next step. If voltage is not zero volt, repair or replace harness or connector between passenger-side air bag module and air bag sensor assembly. 3. Disconnect negative battery cable. Wait at least 90 seconds. Reconnect air bag sensor assembly connector C5 (center connector) to air bag sensor assembly. Connect jumper wire between Yellow/Red wire (circuit P+) and Yellow/Green wire (circuit P-) of air bag sensor assembly side of passenger-side air bag module harness connector. Connect negative battery cable. Wait at least 2 seconds. Turn ignition switch to ACC or ON position. Wait at least 20 seconds. Clear DTCs. See CLEARING CODES under DIAGNOSTICS. Turn ignition switch to LOCK position. Wait at least 20 seconds. Turn ignition switch to ACC or ON position. Wait at least 20 seconds. Retrieve DTCs. See RETRIEVING CODES under DIAGNOSTICS. If DTC 52/B0108 is not displayed, go to next step. If DTC 52/B0108 is displayed, replace air bag sensor assembly. 4. Turn ignition switch to LOCK position. Disconnect negative battery cable. Wait at least 90 seconds. Reconnect passenger-side air bag module harness connector. Connect negative battery cable. Wait at least 2 seconds. Turn ignition switch to ACC or ON position. Wait at least 20 seconds. Clear DTCs. See CLEARING CODES under DIAGNOSTICS. Turn ignition switch to LOCK position. Wait at least 20 seconds. Turn ignition switch to ACC or ON position. Wait at least 20 seconds. Retrieve DTCs. See RETRIEVING CODES under DIAGNOSTICS. If DTC 52/B0108 is not displayed, system is functioning properly at this time. Check for intermittent fault. See AIR BAG WARNING LIGHT INTERMITTENT . If DTC 52/B0108 is displayed, replace passenger-side air bag module. DTC 53/B0105: SHORT IN PASSENGER-SIDE AIR BAG SQUIB CIRCUIT
Description

The passenger-side air bag squib circuit consists of the air bag sensor assembly and passenger-side air bag module. The squib circuit causes the passenger-side air bag to deploy when deployment conditions are satisfied.
Possible Causes

DTC 53/B0105 could be caused by a short in Yellow/Red (circuit P+) and Yellow/Green (circuit P-) wires in passenger-side air bag squib circuit, passenger-side air bag squib malfunction or air bag sensor assembly malfunction. NOTE: During testing, if DTCs other than DTC 53/B0105 are displayed, disregard them.

2002 ACCESSORIES/SAFETY EQUIPMENT Toyota - Air Bag Restraint Systems

Diagnostic Procedure

1. Disable air bag system. See DISABLING SYSTEM under DISABLING & ACTIVATING AIR BAG SYSTEM. 2. Release shorting spring on air bag sensor assembly connector C5 (center connector). See RELEASING SHORTING SPRING under DIAGNOSTICS. Measure resistance between Yellow/Red wire (circuit P+) and Yellow/Green wire (circuit P-) of air bag sensor assembly side of passenger-side air bag module harness connector. See WIRING DIAGRAMS . If resistance is more than one megohm, go to next step. If resistance is less than one megohm, repair or replace harness or connector between passenger-side air bag module and air bag sensor assembly. 3. Reconnect air bag sensor assembly connector C5 (center connector) to air bag sensor assembly. Connect jumper wire between Yellow/Red wire (circuit P+) and Yellow/Green wire (circuit P-) of air bag sensor assembly side of passenger-side air bag module harness connector. Connect negative battery cable. Wait at least 2 seconds. Turn ignition switch to ACC or ON position. Wait at least 20 seconds. Clear DTCs. See CLEARING CODES under DIAGNOSTICS. Turn ignition switch to LOCK position. Wait at least 20 seconds. Turn ignition switch to ACC or ON position. Wait at least 20 seconds. Retrieve DTCs. See RETRIEVING CODES under DIAGNOSTICS. If DTC 53/B0105 is not displayed, go to next step. If DTC 53/B0105 is displayed, replace air bag sensor assembly. 4. Turn ignition switch to LOCK position. Disconnect negative battery cable. Wait at least 90 seconds. Reconnect passenger-side air bag module harness connector. Connect negative battery cable. Wait at least 2 seconds. Turn ignition switch to ACC or ON position. Wait at least 20 seconds. Clear DTCs. See CLEARING CODES under DIAGNOSTICS. Turn ignition switch to LOCK position. Wait at least 20 seconds. Turn ignition switch to ACC or ON position. Wait at least 20 seconds. Retrieve DTCs. See RETRIEVING CODES under DIAGNOSTICS. If DTC 53/B0105 is not displayed, system is functioning properly at this time. Check for intermittent fault. See AIR BAG WARNING LIGHT INTERMITTENT . If DTC 53/B0105 is displayed, replace passenger-side air bag module. DTC 54/B0106: OPEN IN PASSENGER-SIDE AIR BAG SQUIB CIRCUIT
Description

The passenger-side air bag squib circuit consists of the air bag sensor assembly and passenger-side air bag module. The squib circuit causes the passenger-side air bag to deploy when deployment conditions are satisfied.
Possible Causes

DTC 54/B0106 could be caused by an open in Yellow/Red (circuit P+) and Yellow/Green (circuit P-) wires in passenger-side air bag squib circuit, passenger-side air bag squib malfunction or air bag sensor assembly malfunction. NOTE: During testing, if DTCs other than DTC 54/B0106 are displayed, disregard them.

Diagnostic Procedure

1. Disable air bag system. See DISABLING SYSTEM under DISABLING & ACTIVATING AIR BAG SYSTEM. 2. Measure resistance between Yellow/Red wire (circuit P+) and Yellow/Green wire (circuit P-) of air bag sensor assembly side of passenger-side air bag module harness connector. See WIRING

2002 ACCESSORIES/SAFETY EQUIPMENT Toyota - Air Bag Restraint Systems

DIAGRAMS . If resistance is less than one ohm, go to next step. If resistance is more than one ohm, repair or replace harness or connector between passenger-side air bag module and air bag sensor assembly. 3. Reconnect air bag sensor assembly connector C5 (center connector) to air bag sensor assembly. Connect jumper wire between Yellow/Red wire (circuit P+) and Yellow/Green wire (circuit P-) of air bag sensor assembly side of passenger-side air bag module harness connector. Connect negative battery cable. Wait at least 2 seconds. Turn ignition switch to ACC or ON position. Wait at least 20 seconds. Clear DTCs. See CLEARING CODES under DIAGNOSTICS. Turn ignition switch to LOCK position. Wait at least 20 seconds. Turn ignition switch to ACC or ON position. Wait at least 20 seconds. Retrieve DTCs. See RETRIEVING CODES under DIAGNOSTICS. If DTC 54/B0106 is not displayed, go to next step. If DTC 54/B0106 is displayed, replace air bag sensor assembly. 4. Turn ignition switch to LOCK position. Disconnect negative battery cable. Wait at least 90 seconds. Reconnect passenger-side air bag module harness connector. Connect negative battery cable. Wait at least 2 seconds. Turn ignition switch to ACC or ON position. Wait at least 20 seconds. Clear DTCs. See CLEARING CODES under DIAGNOSTICS. Turn ignition switch to LOCK position. Wait at least 20 seconds. Turn ignition switch to ACC or ON position. Wait at least 20 seconds. Retrieve DTCs. See RETRIEVING CODES under DIAGNOSTICS. If DTC 54/B0106 is not displayed, system is functioning properly at this time. Check for intermittent fault. See AIR BAG WARNING LIGHT INTERMITTENT . If DTC 54/B0106 is displayed, replace passenger-side air bag module. DTC 61/B0132: SHORT TO GROUND IN PASSENGER-SIDE SEAT BELT PRETENSIONER SQUIB CIRCUIT
Description

The passenger-side seat belt pretensioner squib circuit consists of the air bag sensor assembly and passenger-side seat belt pretensioner. The squib circuit causes the passenger-side seat belt pretensioner to deploy when deployment conditions are satisfied.
Possible Causes

DTC 61/B0132 could be caused by a short to ground in Yellow/Black (circuit PR+) and Yellow (circuit PR) wires in passenger-side seat belt pretensioner squib circuit, passenger-side seat belt pretensioner squib malfunction or air bag sensor assembly malfunction. NOTE: During testing, if DTCs other than DTC 61/B0132 are displayed, disregard them.

Diagnostic Procedure

1. Disable air bag system. See DISABLING SYSTEM under DISABLING & ACTIVATING AIR BAG SYSTEM. 2. Release shorting spring on air bag sensor assembly connector C6. See RELEASING SHORTING SPRING under DIAGNOSTICS. Measure resistance between ground and Yellow/Black wire (circuit PR+) of air bag sensor assembly side of right seat belt pretensioner squib harness connector. See WIRING DIAGRAMS . If resistance is less than one megohm, repair or replace harness or connector between passenger-side seat belt pretensioner and air bag sensor assembly. If resistance is more than one megohm, go to next step. 3. Reconnect air bag sensor assembly connector C6 (right connector) to air bag sensor assembly. Connect jumper wire between passenger-side seat belt pretensioner squib harness connector

2002 ACCESSORIES/SAFETY EQUIPMENT Toyota - Air Bag Restraint Systems

Yellow/Black wire (circuit PR+) and Yellow wire (circuit PR-). Connect negative battery cable. Wait at least 2 seconds. Turn ignition switch to ACC or ON position. Wait at least 20 seconds. Clear DTCs. See CLEARING CODES under DIAGNOSTICS. Turn ignition switch to LOCK position. Wait at least 20 seconds. Turn ignition switch to ACC or ON position. Wait at least 20 seconds. Retrieve DTCs. See RETRIEVING CODES under DIAGNOSTICS. If DTC 61/B0132 is not displayed, go to next step. If DTC 61/B0132 is displayed, replace air bag sensor assembly. 4. Turn ignition switch to LOCK position. Disconnect negative battery cable. Wait at least 90 seconds. Reconnect passenger-side seat belt pretensioner squib harness connector. Connect negative battery cable. Wait at least 2 seconds. Turn ignition switch to ACC or ON position. Wait at least 20 seconds. Clear DTCs. See CLEARING CODES under DIAGNOSTICS. Turn ignition switch to LOCK position. Wait at least 20 seconds. Turn ignition switch to ACC or ON position. Wait at least 20 seconds. Retrieve DTCs. See RETRIEVING CODES under DIAGNOSTICS. If DTC 61/B0132 is not displayed, system is functioning properly at this time. Check for intermittent fault. See AIR BAG WARNING LIGHT INTERMITTENT . If DTC 61/B0132 is displayed, replace passenger-side seat belt pretensioner. DTC 62/B0133: SHORT TO BATTERY IN PASSENGER-SIDE SEAT BELT PRETENSIONER SQUIB CIRCUIT
Description

The passenger-side seat belt pretensioner squib circuit consists of the air bag sensor assembly and passenger-side seat belt pretensioner. The squib circuit causes the passenger-side seat belt pretensioner to deploy when deployment conditions are satisfied.
Possible Causes

DTC 62/B0133 could be caused by a short to battery in Yellow/Black (circuit PR+) and Yellow (circuit PR) wires in passenger-side seat belt pretensioner squib circuit, passenger-side seat belt pretensioner squib malfunction or air bag sensor assembly malfunction. NOTE: During testing, if DTCs other than DTC 62/B0133 are displayed, disregard them.

Diagnostic Procedure

1. Disable air bag system. See DISABLING SYSTEM under DISABLING & ACTIVATING AIR BAG SYSTEM. Reconnect negative battery cable. 2. Turn ignition switch to ON position. Measure voltage between ground and Yellow/Black wire (circuit PR+) of air bag sensor assembly side of passenger-side seat belt pretensioner squib harness connector. If voltage is not zero volt, repair or replace harness or connector between passenger-side seat belt pretensioner and air bag sensor assembly. If voltage is zero volt, go to next step. 3. Turn ignition switch to LOCK position. Disconnect negative battery cable. Wait at least 90 seconds. Reconnect air bag sensor assembly connector C6 (right connector) to air bag sensor assembly. Connect jumper wire between Yellow/Black wire (circuit PR+) and Yellow wire (circuit PR-) of air bag sensor assembly side of passenger-side seat belt pretensioner squib harness connector. Connect negative battery cable. Wait at least 2 seconds. Turn ignition switch to ACC or ON position. Wait at least 20 seconds. Clear DTCs. See CLEARING CODES under DIAGNOSTICS. Turn ignition switch to LOCK position. Wait at least 20 seconds. Turn ignition switch to ACC or ON position. Wait at least 20 seconds. Retrieve DTCs. See RETRIEVING CODES under DIAGNOSTICS. If DTC

2002 ACCESSORIES/SAFETY EQUIPMENT Toyota - Air Bag Restraint Systems

62/B0133 is not displayed, go to next step. If DTC 62/B0133 is displayed, replace air bag sensor assembly. 4. Turn ignition switch to LOCK position. Disconnect negative battery cable. Wait at least 90 seconds. Reconnect passenger-side seat belt pretensioner harness connector. Connect negative battery cable. Wait at least 2 seconds. Turn ignition switch to ACC or ON position. Wait at least 20 seconds. Clear DTCs. See CLEARING CODES under DIAGNOSTICS. Turn ignition switch to LOCK position. Wait at least 20 seconds. Turn ignition switch to ACC or ON position. Wait at least 20 seconds. Retrieve DTCs. See RETRIEVING CODES under DIAGNOSTICS. If DTC 62/B0133 is not displayed, system is functioning properly at this time. Check for intermittent fault. See AIR BAG WARNING LIGHT INTERMITTENT . If DTC 62/B0133 is displayed, replace passenger-side seat belt pretensioner. DTC 63/B0130: SHORT IN PASSENGER-SIDE SEAT BELT PRETENSIONER SQUIB CIRCUIT
Description

The passenger-side seat belt pretensioner squib circuit consists of the air bag sensor assembly and passenger-side seat belt pretensioner. The squib circuit causes the passenger-side seat belt pretensioner to deploy when deployment conditions are satisfied.
Possible Causes

DTC 63/B0130 could be caused by a short between Yellow/Black (circuit PR+) and Yellow (circuit PR-) wires in passenger-side seat belt pretensioner squib circuit, passenger-side seat belt pretensioner squib malfunction or air bag sensor assembly malfunction. NOTE: During testing, if DTCs other than DTC 63/B0130 are displayed, disregard them.

Diagnostic Procedure

1. Disable air bag system. See DISABLING SYSTEM under DISABLING & ACTIVATING AIR BAG SYSTEM. 2. Release shorting spring on air bag sensor assembly connector C6. See RELEASING SHORTING SPRING under DIAGNOSTICS. Measure resistance between passenger-side seat belt pretensioner squib harness connector Yellow/Black wire (circuit PR+) and Yellow wire (circuit PR-). See WIRING DIAGRAMS . If resistance is less than one megohm, repair or replace harness or connector between passenger-side seat belt pretensioner and air bag sensor assembly. If resistance is more than one megohm, go to next step. 3. Reconnect air bag sensor assembly connector C6 (right connector) to air bag sensor assembly. Connect jumper wire between Yellow/Black wire (circuit PR+) and Yellow wire (circuit PR-) air bag sensor assembly side of passenger-side seat belt pretensioner squib harness connector. Connect negative battery cable. Wait at least 2 seconds. Turn ignition switch to ACC or ON position. Wait at least 20 seconds. Clear DTCs. See CLEARING CODES under DIAGNOSTICS. Turn ignition switch to LOCK position. Wait at least 20 seconds. Turn ignition switch to ACC or ON position. Wait at least 20 seconds. Retrieve DTCs. See RETRIEVING CODES under DIAGNOSTICS. If DTC 63/B0130 is not displayed, go to next step. If DTC 63/B0130 is displayed, replace air bag sensor assembly. 4. Turn ignition switch to LOCK position. Disconnect negative battery cable. Wait at least 90 seconds. Reconnect passenger-side seat belt pretensioner harness connector. Connect negative battery cable.

2002 ACCESSORIES/SAFETY EQUIPMENT Toyota - Air Bag Restraint Systems

Wait at least 2 seconds. Turn ignition switch to ACC or ON position. Wait at least 20 seconds. Clear DTCs. See CLEARING CODES under DIAGNOSTICS. Turn ignition switch to LOCK position. Wait at least 20 seconds. Turn ignition switch to ACC or ON position. Wait at least 20 seconds. Retrieve DTCs. See RETRIEVING CODES under DIAGNOSTICS. If DTC 63/B0130 is not displayed, system is functioning properly at this time. Check for intermittent fault. See AIR BAG WARNING LIGHT INTERMITTENT . If DTC 63/B0130 is displayed, replace passenger-side seat belt pretensioner. DTC 64/B0131: OPEN IN PASSENGER-SIDE SEAT BELT PRETENSIONER SQUIB CIRCUIT
Description

The passenger-side seat belt pretensioner squib circuit consists of the air bag sensor assembly and passenger-side seat belt pretensioner. The squib circuit causes the passenger-side seat belt pretensioner to deploy when deployment conditions are satisfied.
Possible Causes

DTC 64/B0131 could be caused by an open in Yellow/Black (circuit PR+) or Yellow (circuit PR-) wires in passenger-side seat belt pretensioner squib circuit, passenger-side seat belt pretensioner squib malfunction or air bag sensor assembly malfunction. NOTE: During testing, if DTCs other than DTC 64/B0131 are displayed, disregard them.

Diagnostic Procedure

1. Disable air bag system. See DISABLING SYSTEM under DISABLING & ACTIVATING AIR BAG SYSTEM. 2. Measure resistance between passenger-side seat belt pretensioner squib harness connector Yellow/Black wire (circuit PR+) and Yellow wire (circuit PR-). See WIRING DIAGRAMS . If resistance is more than one ohm, repair or replace harness or connector between passenger-side seat belt pretensioner and air bag sensor assembly. If resistance is less than one ohm, go to next step. 3. Reconnect air bag sensor assembly connector C6 (right connector) to air bag sensor assembly. Connect jumper wire between Yellow/Black wire (circuit PR+) and Yellow wire (circuit PR-) of air bag sensor assembly side of passenger-side seat belt pretensioner squib harness connector. Connect negative battery cable. Wait at least 2 seconds. Turn ignition switch to ACC or ON position. Wait at least 20 seconds. Clear DTCs. See CLEARING CODES under DIAGNOSTICS. Turn ignition switch to LOCK position. Wait at least 20 seconds. Turn ignition switch to ACC or ON position. Wait at least 20 seconds. Retrieve DTCs. See RETRIEVING CODES under DIAGNOSTICS. If DTC 64/B0131 is not displayed, go to next step. If DTC 64/B0131 is displayed, replace air bag sensor assembly. 4. Turn ignition switch to LOCK position. Disconnect negative battery cable. Wait at least 90 seconds. Reconnect passenger-side seat belt pretensioner connector. Connect negative battery cable. Wait at least 2 seconds. Turn ignition switch to ACC or ON position. Wait at least 20 seconds. Clear DTCs. See CLEARING CODES under DIAGNOSTICS. Turn ignition switch to LOCK position. Wait at least 20 seconds. Turn ignition switch to ACC or ON position. Wait at least 20 seconds. Retrieve DTCs. See RETRIEVING CODES under DIAGNOSTICS. If DTC 64/B0131 is not displayed, system is functioning properly at this time. Check for intermittent fault. See AIR BAG WARNING LIGHT INTERMITTENT . If DTC 64/B0131 is displayed, replace passenger-side seat belt

2002 ACCESSORIES/SAFETY EQUIPMENT Toyota - Air Bag Restraint Systems

pretensioner. DTC 71/B0137: SHORT TO GROUND IN DRIVER-SIDE SEAT BELT PRETENSIONER SQUIB CIRCUIT
Description

The driver-side seat belt pretensioner squib circuit consists of the air bag sensor assembly and driver-side seat belt pretensioner. The squib circuit causes the driver-side seat belt pretensioner to deploy when deployment conditions are satisfied.
Possible Causes

DTC 71/B0137 could be caused by a short to ground in Yellow/Black (circuit PL+) and Yellow (circuit PL-) wires in driver-side seat belt pretensioner squib circuit, driver-side seat belt pretensioner squib malfunction or air bag sensor assembly malfunction. NOTE: During testing, if DTCs other than DTC 71/B0137 are displayed, disregard them.

Diagnostic Procedure

1. Disable air bag system. See DISABLING SYSTEM under DISABLING & ACTIVATING AIR BAG SYSTEM. 2. Measure resistance between ground and Yellow/Black wire (circuit PR+) of air bag sensor assembly side of driver-side seat belt pretensioner squib harness connector. If resistance is less than one megohm, repair or replace harness or connector between driver-side seat belt pretensioner and air bag sensor assembly. If resistance is more than one megohm, go to next step. 3. Reconnect air bag sensor assembly connector C4 (left connector) to air bag sensor assembly. Connect jumper wire between Yellow/Black wire (circuit PL+) and Yellow wire (circuit PL-) of air bag sensor assembly side of driver-side seat belt pretensioner squib harness connector. Connect negative battery cable. Wait at least 2 seconds. Turn ignition switch to ACC or ON position. Wait at least 20 seconds. Clear DTCs. See CLEARING CODES under DIAGNOSTICS. Turn ignition switch to LOCK position. Wait at least 20 seconds. Turn ignition switch to ACC or ON position. Wait at least 20 seconds. Retrieve DTCs. See RETRIEVING CODES under DIAGNOSTICS. If DTC 71/B0137 is not displayed, go to next step. If DTC 71/B0137 is displayed, replace air bag sensor assembly. 4. Turn ignition switch to LOCK position. Disconnect negative battery cable. Wait at least 90 seconds. Reconnect driver-side seat belt pretensioner connector. Connect negative battery cable. Wait at least 2 seconds. Turn ignition switch to ACC or ON position. Wait at least 20 seconds. Clear DTCs. See CLEARING CODES under DIAGNOSTICS. Turn ignition switch to LOCK position. Wait at least 20 seconds. Turn ignition switch to ACC or ON position. Wait at least 20 seconds. Retrieve DTCs. See RETRIEVING CODES under DIAGNOSTICS. If DTC 71/B0137 is not displayed, system is functioning properly at this time. Check for intermittent fault. See AIR BAG WARNING LIGHT INTERMITTENT . If DTC 71/B0137 is displayed, replace driver-side seat belt pretensioner. DTC 72/B0138: SHORT TO BATTERY IN DRIVER-SIDE SEAT BELT PRETENSIONER SQUIB CIRCUIT
Description

2002 ACCESSORIES/SAFETY EQUIPMENT Toyota - Air Bag Restraint Systems

The driver-side seat belt pretensioner squib circuit consists of the air bag sensor assembly and driver-side seat belt pretensioner. The squib circuit causes the driver-side seat belt pretensioner to deploy when deployment conditions are satisfied.
Possible Causes

DTC 72/B0138 could be caused by a short to battery in Yellow/Black (circuit PL+) and Yellow (circuit PL-) wires in driver-side seat belt pretensioner squib circuit, driver-side seat belt pretensioner squib malfunction or air bag sensor assembly malfunction. NOTE: During testing, if DTCs other than DTC 72/B0138 are displayed, disregard them.

Diagnostic Procedure

1. Disable air bag system. See DISABLING SYSTEM under DISABLING & ACTIVATING AIR BAG SYSTEM. Reconnect negative battery cable. 2. Turn ignition switch to ON position. Measure voltage between ground and Yellow/Black wire (circuit PL+) of air bag sensor assembly side of driver-side seat belt pretensioner squib harness connector. See WIRING DIAGRAMS . If voltage is not zero volt, repair or replace harness or connector between driver-side seat belt pretensioner and air bag sensor assembly. If voltage is zero volt, go to next step. 3. Turn ignition switch to LOCK position. Disconnect negative battery cable. Wait at least 90 seconds. Reconnect air bag sensor assembly connector C4 (left connector) to air bag sensor assembly. Connect jumper wire between Yellow/Black wire (circuit PL+) and Yellow wire (circuit PL-) of air bag sensor assembly side of driver-side seat belt pretensioner squib harness connector. Connect negative battery cable. Wait at least 2 seconds. Turn ignition switch to ACC or ON position. Wait at least 20 seconds. Clear DTCs. See CLEARING CODES under DIAGNOSTICS. Turn ignition switch to LOCK position. Wait at least 20 seconds. Turn ignition switch to ACC or ON position. Wait at least 20 seconds. Retrieve DTCs. See RETRIEVING CODES under DIAGNOSTICS. If DTC 72/B0138 is not displayed, go to next step. If DTC 72/B0138 is displayed, replace air bag sensor assembly. 4. Turn ignition switch to LOCK position. Disconnect negative battery cable. Wait at least 90 seconds. Reconnect driver-side seat belt pretensioner connector. Connect negative battery cable. Wait at least 2 seconds. Turn ignition switch to ACC or ON position. Wait at least 20 seconds. Clear DTCs. See CLEARING CODES under DIAGNOSTICS. Turn ignition switch to LOCK position. Wait at least 20 seconds. Turn ignition switch to ACC or ON position. Wait at least 20 seconds. Retrieve DTCs. See RETRIEVING CODES under DIAGNOSTICS. If DTC 72/B0138 is not displayed, system is functioning properly at this time. Check for intermittent fault. See AIR BAG WARNING LIGHT INTERMITTENT . If DTC 72/B0138 is displayed, replace driver-side seat belt pretensioner. DTC 73/B0135: SHORT IN DRIVER-SIDE SEAT BELT PRETENSIONER SQUIB CIRCUIT
Description

The driver-side seat belt pretensioner squib circuit consists of the air bag sensor assembly and driver-side seat belt pretensioner. The squib circuit causes the driver-side seat belt pretensioner to deploy when deployment conditions are satisfied.
Possible Causes

DTC 73/B0135 could be caused by a short between Yellow/Black (circuit PL+) and Yellow (circuit PL-)

2002 ACCESSORIES/SAFETY EQUIPMENT Toyota - Air Bag Restraint Systems

wires in driver-side seat belt pretensioner squib circuit, driver-side seat belt pretensioner squib malfunction or air bag sensor assembly malfunction. NOTE: During testing, if DTCs other than DTC 73/B0135 are displayed, disregard them.

Diagnostic Procedure

1. Disable air bag system. See DISABLING SYSTEM under DISABLING & ACTIVATING AIR BAG SYSTEM. 2. Release shorting spring on air bag sensor assembly connector C4. See RELEASING SHORTING SPRING under DIAGNOSTICS. Measure resistance between Yellow/Black wire (circuit PL+) and Yellow wire (circuit PL-) of air bag sensor assembly side of driver-side seat belt pretensioner squib harness connector. See WIRING DIAGRAMS . If resistance is less than one megohm, repair or replace harness or connector between driver-side seat belt pretensioner and air bag sensor assembly. If resistance is more than one megohm, go to next step. 3. Reconnect air bag sensor assembly connector C4 (left connector) to air bag sensor assembly. Connect jumper wire between Yellow/Black wire (circuit PL+) and Yellow wire (circuit PL-) air bag sensor assembly side of driver-side seat belt pretensioner squib harness connector. Connect negative battery cable. Wait at least 2 seconds. Turn ignition switch to ACC or ON position. Wait at least 20 seconds. Clear DTCs. See CLEARING CODES under DIAGNOSTICS. Turn ignition switch to LOCK position. Wait at least 20 seconds. Turn ignition switch to ACC or ON position. Wait at least 20 seconds. Retrieve DTCs. See RETRIEVING CODES under DIAGNOSTICS. If DTC 73/B0135 is not displayed, go to next step. If DTC 73/B0135 is displayed, replace air bag sensor assembly. 4. Turn ignition switch to LOCK position. Disconnect negative battery cable. Wait at least 90 seconds. Reconnect driver-side seat belt pretensioner connector. Connect negative battery cable. Wait at least 2 seconds. Turn ignition switch to ACC or ON position. Wait at least 20 seconds. Clear DTCs. See CLEARING CODES under DIAGNOSTICS. Turn ignition switch to LOCK position. Wait at least 20 seconds. Turn ignition switch to ACC or ON position. Wait at least 20 seconds. Retrieve DTCs. See RETRIEVING CODES under DIAGNOSTICS. If DTC 73/B0135 is not displayed, system is functioning properly at this time. Check for intermittent fault. See AIR BAG WARNING LIGHT INTERMITTENT . If DTC 73/B0135 is displayed, replace driver-side seat belt pretensioner. DTC 74/B0136: OPEN IN DRIVER-SIDE SEAT BELT PRETENSIONER SQUIB CIRCUIT
Description

The driver-side seat belt pretensioner squib circuit consists of the air bag sensor assembly and driver-side seat belt pretensioner. The squib circuit causes the driver-side seat belt pretensioner to deploy when deployment conditions are satisfied.
Possible Causes

DTC 74/B0136 could be caused by an open in Yellow/Black (circuit PL+) or Yellow (circuit PL-) wires in driver-side seat belt pretensioner squib circuit, driver-side seat belt pretensioner squib malfunction or air bag sensor assembly malfunction. NOTE: During testing, if DTCs other than DTC 74/B0136 are displayed, disregard them.

2002 ACCESSORIES/SAFETY EQUIPMENT Toyota - Air Bag Restraint Systems

Diagnostic Procedure

1. Disable air bag system. See DISABLING SYSTEM under DISABLING & ACTIVATING AIR BAG SYSTEM. 2. Measure resistance between Yellow/Black wire (circuit PL+) and Yellow wire (circuit PL-) of air bag sensor assembly side of driver-side seat belt pretensioner squib harness connector. See WIRING DIAGRAMS . If resistance is more than one ohm, repair or replace harness or connector between driver-side seat belt pretensioner and air bag sensor assembly. If resistance is less than one ohm, go to next step. 3. Reconnect air bag sensor assembly connector C4 (left connector) to air bag sensor assembly. Connect jumper wire between Yellow/Black wire (circuit PL+) and Yellow wire (circuit PL-) of air bag sensor assembly side of driver-side seat belt pretensioner squib harness connector. Connect negative battery cable. Wait at least 2 seconds. Turn ignition switch to ACC or ON position. Wait at least 20 seconds. Clear DTCs. See CLEARING CODES under DIAGNOSTICS. Turn ignition switch to LOCK position. Wait at least 20 seconds. Turn ignition switch to ACC or ON position. Wait at least 20 seconds. Retrieve DTCs. See RETRIEVING CODES under DIAGNOSTICS. If DTC 74/B0136 is not displayed, go to next step. If DTC 74/B0136 is displayed, replace air bag sensor assembly. 4. Turn ignition switch to LOCK position. Disconnect negative battery cable. Wait at least 90 seconds. Reconnect driver-side seat belt pretensioner connector. Connect negative battery cable. Wait at least 2 seconds. Turn ignition switch to ACC or ON position. Wait at least 20 seconds. Clear DTCs. See CLEARING CODES under DIAGNOSTICS. Turn ignition switch to LOCK position. Wait at least 20 seconds. Turn ignition switch to ACC or ON position. Wait at least 20 seconds. Retrieve DTCs. See RETRIEVING CODES under DIAGNOSTICS. If DTC 74/B0136 is not displayed, system is functioning properly at this time. Check for intermittent fault. See AIR BAG WARNING LIGHT INTERMITTENT . If DTC 74/B0136 is displayed, replace driver-side seat belt pretensioner.

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS Application Air bag sensor assembly screw Front air bag sensor bolt Passenger-side air bag bolt/nut Pretensioner lower bolt Seat back bolts Seat track bolts Side air bag sensor screw Steering wheel retaining nut Driver-side air bag module screw Pretensioner upper bolt Side air bag module nut Ft. Lbs. (N.m) 15 (20) 15 (20) 15 (20) 30 (41) 32 (43) 27 (37) 15 (20) 37 (50) INCH Lbs. (N.m) 78 (8.8) 43 (4.9) 53 (6.0)

WIRING DIAGRAMS

2002 ACCESSORIES/SAFETY EQUIPMENT Toyota - Air Bag Restraint Systems

Fig. 17: Air Bag System Wiring Diagram (Corolla)

2002 EXTERIOR/INTERIOR TRIM Body - Corolla

2002 EXTERIOR/INTERIOR TRIM Body - Corolla

CLIP
REPLACEMENT The removal and installation methods of typical clips used in body parts are shown below. NOTE: If the clip is damaged during the operation, always replace it with a new clip.

2002 EXTERIOR/INTERIOR TRIM Body - Corolla

Fig. 1: Identifying Clip Installation & Removal Procedure (1 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 EXTERIOR/INTERIOR TRIM Body - Corolla

Fig. 2: Identifying Clip Installation & Removal Procedure (1 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

SRS AIRBAG
PRECAUTION The COROLLA is equipped with an SRS (Supplemental Restraint System) such as the driver AIRBAG, front passenger AIRBAG, side AIRBAG and set belt pretensioner. Failure to carry out service operation in the correct sequence could cause the SRS to unexpectedly deploy during servicing, possibly leading to a serious accident. Before servicing (including removal or installation of parts, inspection or replacement), be sure to read the precautionary notices. See AIR BAG SAFETY PRECAUTIONS .

FRONT BUMPER
COMPONENTS

2002 EXTERIOR/INTERIOR TRIM Body - Corolla

Fig. 3: Locating Front Bumper Components Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

REAR BUMPER
COMPONENTS

2002 EXTERIOR/INTERIOR TRIM Body - Corolla

Fig. 4: Locating Rear Bumper Components Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

HEADLIGHT
COMPONENTS

2002 EXTERIOR/INTERIOR TRIM Body - Corolla

Fig. 5: Locating Headlight Components Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL 1. Remove front bumper cover. See FRONT BUMPER . 2. Remove headlight : a. Remove the screw. b. Disconnect the connector, then remove the turn signal light. c. Remove the 2 bolts and nut.

2002 EXTERIOR/INTERIOR TRIM Body - Corolla

Fig. 6: Locating Headlight Mounting Bolts & Nut Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. d. Disconnect the connectors, then remove the headlight. e. Employ the same manner described above to the other side. INSTALLATION NOTE: At the time of installation, if the shown part of the headlight is damaged, the headlight can be reinstalled to the body by installing a bracket to it. See Fig. 7.

2002 EXTERIOR/INTERIOR TRIM Body - Corolla

Fig. 7: Identifying Substitutable Headlight Component Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Installation is in the reverse order of removal. See REMOVAL .

HOOD
ADJUSTMENT NOTE: Since the centering bolt is used as the hood hinge and lock set bolt, the hood and lock can not be adjusted with it on. Substitute a bolt and washer for the centering bolt.

2002 EXTERIOR/INTERIOR TRIM Body - Corolla

Fig. 8: Identifying Centering Bolt & Bolt With Washer For Substitution Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 1. Adjust hood in forward/rearward and left/right directions :

2002 EXTERIOR/INTERIOR TRIM Body - Corolla

Fig. 9: Identifying Hood Adjustment Directions Controlled By Top/Hood Side Of Hood Hinge Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Adjust the hood by loosening the hood side hinge bolts. Torque: 13 N.m (130 kgf.cm, 9 ft.lbf) 2. Adjust front edge of hood in vertical direction

2002 EXTERIOR/INTERIOR TRIM Body - Corolla

Fig. 10: Locating Vertical Hood Adjuster Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Adjust the hood by tuning the cushions. 3. Adjust hood lock :

2002 EXTERIOR/INTERIOR TRIM Body - Corolla

Fig. 11: Identifying Hood Lock Adjustment Directions Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Adjust the lock by loosening the bolts. Torque: 7.8 N.m (80 kgf.cm, 69 in. lbf)

FRONT DOOR
COMPONENTS

2002 EXTERIOR/INTERIOR TRIM Body - Corolla

Fig. 12: Locating Front Door Components Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. DISASSEMBLY NOTE: At the time of assembly, with door window fully closed, install the plate and the regulator handle with the snap ring.

2002 EXTERIOR/INTERIOR TRIM Body - Corolla

Fig. 13: Identifying Correct Window Regulator Handle Installation Position Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 EXTERIOR/INTERIOR TRIM Body - Corolla

Fig. 14: Removing Window Regulator Handle (W/O Power Window) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 1. W/O Power window, Remove regulator handle : Pull off the snap ring with a shop rag and remove the regulator handle and plate. 2. Remove door inside handle : a. Remove the screw and slide the handle forward.

2002 EXTERIOR/INTERIOR TRIM Body - Corolla

Fig. 15: Removing Door Handle (Inside Vehicle) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disconnect the handle from the control link and remove the handle. W/Power window, remove power window switch Remove armrest panel . Remove lower frame bracket garnish . Remove outside rear view mirror . Torque: 7.8 N-m (80 kgf.cm, 69 in..lbf) . 7. Remove front door trim : a. Remove the clip and 2 screws.

3. 4. 5. 6.

2002 EXTERIOR/INTERIOR TRIM Body - Corolla

Fig. 16: Locating Front Door Trim Clips & Mounting Screw Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 EXTERIOR/INTERIOR TRIM Body - Corolla

CAUTION: Be careful not to damage the door and door trim. Tape the screwdriver tip before use. b. Insert a screwdriver between the door and door trim to pry out. c. Pull the trim upwards to remove it. 8. Remove service hole cover : NOTE: At the time of assembly, do not block the grommet sealing with the cover.

a. Remove the 2 grommets. NOTE: At the time of assembly, bring out the link through the service hole cover.

b. Remove the service hole cover. 9. Remove outside rear view mirror : a. W/Power remote control mirror: Disconnect the connector. b. Remove the 3 nuts and mirror. 10. Remove door glass : a. Remove the hole plug. b. Remove the 2 bolts and door glass. Torque: 8.3 N.m (85 kgf.cm, 74 in. lbf) c. Remove the glass run. 11. Remove door belt moulding : a. Remove the clip. NOTE: Tape the scraper tip before use.

2002 EXTERIOR/INTERIOR TRIM Body - Corolla

Fig. 17: Exploded Side View Of Door Belt Moulding Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Using a scraper, remove the door belt moulding. 12. Remove service hole plate : Remove the 2 screws and plate. NOTE: At the time of assembly, using an air riveter, strike rivets into the door frame to install the speaker to the door frame.

2002 EXTERIOR/INTERIOR TRIM Body - Corolla

Fig. 18: Installing Speaker Rivets Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. If the rivet is not positioned perpendicularly it will bend the mandrel. When the trigger is then pulled, it may damage SST.

2002 EXTERIOR/INTERIOR TRIM Body - Corolla

Fig. 19: Identifying Mandrel & Example Of Incorrect Rivet Installation Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. CAUTION: The cut rivet and rivet cutter will be hot, avoid touching them. Do not jiggle the rivet cutter while cutting. You may enlarge the rivet hole or damage the rivet cutter. Do not drill the door inner hole. 13. Remove speaker : a. Using a drill of less then 0 4.8 mm (0.189 in.), drill out the rivet heads and remove the speaker.

2002 EXTERIOR/INTERIOR TRIM Body - Corolla

Fig. 20: Drilling Speaker Rivets Out Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Using a vacuum cleaner, remove the drilled rivet and the dust from the inside of the door. 14. Remove lower frame . NOTE: Remove the regulator through the service hole. At the time or assembly, apply MP grease to the window regulator. Do not apply grease to the spring of the window regulator.

2002 EXTERIOR/INTERIOR TRIM Body - Corolla

Fig. 21: Identifying Service Regulator MP Grease Application Points (Front Door) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 15. Remove window regulator : a. W/Power window, disconnect the connector. b. W/Power window, remove the 6 bolts and window regulator.

2002 EXTERIOR/INTERIOR TRIM Body - Corolla

Torque: 11.3 N.m (115 kgf.cm, 8 ft.lbf) c. W/O Power window, remove the 5 bolts and window regulator. Torque: 11.3 N.m (115 kgf.cm, 8 ft.lbf) 16. Remove door lock :

2002 EXTERIOR/INTERIOR TRIM Body - Corolla

2002 EXTERIOR/INTERIOR TRIM Body - Corolla

Fig. 22: Identifying Door Lock Mounting Bolts (Front Door) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. a. b. c. d. Remove the door lock control knob. Disconnect the control link from the door lock. Disconnect the links from the outside handle and key cylinder. W/Power door lock, disconnect the connector. NOTE: At the time of assembly, apply adhesive to 3 screws.

e. Remove the 3 screws. Torque: 4.9 N.m (50 kgf.cm, 43 in. lbf) Adhesive: Part No. 08833-00070, THREE BOND 1324 or equivalent. NOTE: At the time of assembly, apply MP grease to the sliding and rotating parts of the door lock.

Fig. 23: Identifying Door Lock MP Grease Application Points (Front Door) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 EXTERIOR/INTERIOR TRIM Body - Corolla

f. Remove the door lock through the service hole. 17. Remove outside handle : a. Remove the 2 bolts and outside handle with key cylinder. Torque: 5.4 N.m (55 kgf.cm, 47 in. lbf) b. Remove the bolt and key cylinder from the outside handle. ADJUSTMENT 1. Adjust door in forward/rearward and vertical directions : Using SST, adjust the door by loosening the body side hinge bolts.

Fig. 24: Identifying Door Adjustment Directions Controlled By Body Side Hinge (Front Door) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. SST 09812-00010 Torque: 25 N.m (260 kgf.cm, 19 ft.lbf) NOTE: Substitute the bolt with washer for the centering bolt. See Fig. 8 .

2002 EXTERIOR/INTERIOR TRIM Body - Corolla

Fig. 25: Identifying Door Adjustment Directions Controlled By Door Side Hinge (Front Door) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 2. Adjust door in left/right and vertical directions : Loosen the door side hinge bolts to adjust. Torque: 25 N.m (260 kgf.cm, 19 ft.lbf) 3. Adjust door lock striker : a. Check that the door fit and door lock linkages are adjusted correctly. b. Loosen the striker mounting screws to adjust. Torque: 23 N.m (230 kgf.cm, 17 ft.lbf) c. Using a plastic hammer, tap the striker to adjust it.

2002 EXTERIOR/INTERIOR TRIM Body - Corolla

Fig. 26: Adjusting Door Lock Striker Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REASSEMBLY Reassembly is in the reverse order of disassembly . See DISASSEMBLY .

REAR DOOR
COMPONENTS

2002 EXTERIOR/INTERIOR TRIM Body - Corolla

Fig. 27: Locating Rear Door Components Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. DISASSEMBLY NOTE: At the time of assembly, with door window fully closed, install the plate and the regulator handle with the snap ring.

2002 EXTERIOR/INTERIOR TRIM Body - Corolla

Fig. 28: Identifying Correct Window Regulator Handle Installation Position Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 EXTERIOR/INTERIOR TRIM Body - Corolla

Fig. 29: Removing Window Regulator Handle (W/O Power Window) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 1. W/O Power window, remove regulator handle . Pull off the snap ring with a shop rag and remove the regulator handle and plate. 2. Remove door inside handle : a. Remove the screw and slide the handle forward.

2002 EXTERIOR/INTERIOR TRIM Body - Corolla

Fig. 30: Removing Door Handle (Inside Vehicle) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disconnect the handle from the control link and remove the handle. 3. W/Power window, remove power window switch . . 4. Remove armrest panel . 5. Remove door trim : a. Remove the 2 screws and 2 clips.

2002 EXTERIOR/INTERIOR TRIM Body - Corolla

Fig. 31: Locating Rear Door Trim Clips & Mounting Screw Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. CAUTION: Be careful not to damage the door and door trim.

2002 EXTERIOR/INTERIOR TRIM Body - Corolla

Tape the screwdriver tip before use. b. Insert a screwdriver between the door and door trim to pry out. c. Pull the trim upward to remove it. NOTE: At the time of assembly, do not block the trim clip sealing with the service hole cover. Bring out the links through the service hole cover.

6. Remove service hole cover : Remove the 2 grommets and cover. 7. Remove door glass run . 8. Remove division bar : Remove the 3 screws and division bar.

2002 EXTERIOR/INTERIOR TRIM Body - Corolla

Fig. 32: Locating Division Bar Mounting Screws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 9. Remove door glass . 10. Remove door glass run . 11. Remove quarter window glass with weatherstrip . NOTE: Tape the scraper tip before use.

2002 EXTERIOR/INTERIOR TRIM Body - Corolla

Fig. 33: Locating Door Belt Moulding Clips Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 12. Remove door belt moulding : Using a scraper, remove the door belt moulding. NOTE: Remove the regulator through the service hole. At the time of assembly, apply MP grease to the window regulator. At the time of assembly, do not apply grease to the spring of the window regulator.

2002 EXTERIOR/INTERIOR TRIM Body - Corolla

Fig. 34: Locating Window Regulator MP Grease Application Points (Rear Door) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 13. Remove window regulator : a. W/Power window, disconnect the connector, then remove the 4 bolts and window regulator.

2002 EXTERIOR/INTERIOR TRIM Body - Corolla

Torque: 5.4 N.m (55 kgf.cm, 48 in. lbf) b. W/O Power window, remove the 3 bolts and window regulator. Torque: 5.4 N.m (55 kgf.cm, 48 in. lbf) NOTE: At the time of assembly, apply MP grease to the sliding and rotating parts of the door lock.

Fig. 35: Identifying Door Lock MP Grease Applications Points (Rear Door) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 EXTERIOR/INTERIOR TRIM Body - Corolla

Fig. 36: Locating Door Lock Mounting Bolts (Rear Door) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 14. Remove door lock :

2002 EXTERIOR/INTERIOR TRIM Body - Corolla

a. b. c. d. e. f. g.

Remove the door lock control knob from the link. Remove the door locking link guide. Using a clip remover, remove the bellcrank and clamp. Remove the links from the clamps. Remove the link from the outside handle. W/Power door lock, disconnect the connector. W/Power door lock, remove the bolt, 3 screws and door lock with control links. Torque: Screw: 4.9 N.m (50 kgf.cm, 43 in. lbf) NOTE: At the time of assembly, apply adhesive to the 3 screws.

h. W/O Power door lock, remove the 3 screws and door lock with control links. Torque: 4.9 N.m (50 kgf.cm, 43 in. lbf) . Adhesive : Part No. 08833-00700, THREE BOND 1324 or equivalent . 1. Remove the link protector and control links from the door lock. 2. Remove the silencer pad from the door panel. 15. Remove outside handle Torque: 5.4 N.m (55 kgf.cm, 47 in. lbf) ADJUSTMENT 1. Adjust door in forward/rearward and vertical directions : a. Remove front door scuff plate. b. Remove center pillar lower garnish. c. Remove the front seat bolt. See SEAT BELT PRETENSIONER . d. Loosen the body side hinge nuts to adjust.

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Fig. 37: Identifying Door Adjustment Directions Controlled By Body Side Hinge (Rear Door) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Torque: 25 N.m (260 kgf.cm, 19 ft.lbf) e. Install the removed parts. 2. Adjust door in left/right and vertical directions :

2002 EXTERIOR/INTERIOR TRIM Body - Corolla

Fig. 38: Identifying Door Adjustment Directions Controlled By Body Side Hinge (Rear Door) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Loosen the door side hinge bolts to adjust. Torque: 25 N.m (260 kgf.cm, 19 ft.lbf) 3. Adjust door lock striker : a. Check that the door fit and door lock linkages are adjusted correctly. b. Loosen the striker mounting screws to adjust. Torque: 23 N.m (230 kgf.cm, 17 ft.lbf) c. Using a plastic hammer, tap the striker to adjust it.

2002 EXTERIOR/INTERIOR TRIM Body - Corolla

Fig. 39: Adjusting Door Lock Striker Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REASSEMBLY Reassembly is in the reverse order of disassembly. See DISASSEMBLY .

LUGGAGE COMPARTMENT DOOR AND HINGE

COMPONENTS

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Fig. 40: Locating Luggage Compartment Door & Hinge Components Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL 1. Remove luggage compartment door : Remove the 4 bolts and door. Torque: 6.9 N.m (70 kgf.cm, 61 in. lbf)

2002 EXTERIOR/INTERIOR TRIM Body - Corolla

2. 3. 4. 5. 6. 7.

Remove luggage compartment mat . Remove rear floor finish plate . Remove rear floor finish side plate . Remove inner luggage compartment trim . Remove rear seat . See REMOVAL . Remove high-mounted stop light : a. Push on the both sides of the cover to release the claws by your hand and remove the cover.

Fig. 41: Locating High-Mounted Stop Light Clips & Identifying Removal Direction Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the stop light, then disconnect the connector. 8. Remove roof side inner garnish : NOTE: Tape the screwdriver tip before use.

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Fig. 42: Locating Roof Side Inner Garnish Clips Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. a. Using a screwdriver, remove the garnish. b. Employ the same manner described above to the other side. 9. Remove tether anchor : NOTE: Tape the screwdriver tip before use.

a. Using a screwdriver, remove the CRS tether anchor cover. b. Remove the tether anchor by loosening the bolt. c. Employ the same manner described above to the other sides. 10. Remove package tray trim . 11. Remove torsion bar : a. Install SST to the torsion bar on the hinge side. SST 09804-24010

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Fig. 43: Removing Torsion Bar (1 Of 3) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Push down SST, and pull the luggage compartment door hinge from the torsion bar.

2002 EXTERIOR/INTERIOR TRIM Body - Corolla

Fig. 44: Removing Torsion Bar (2 Of 3) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Slowly lift SST, and remove the torsion bar from the torsion bar bracket with SST.

2002 EXTERIOR/INTERIOR TRIM Body - Corolla

Fig. 45: Removing Torsion Bar (3 Of 3) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. d. Disconnect the torsion bar from the bracket. e. Employ the same manner described above to the other side. 12. Remove luggage compartment door hinges : Remove the 2 pins and hinges. DISASSEMBLY 1. Remove door lock : a. Disconnect the control link. b. Remove the 2 bolts and lock.

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Torque: 4.9 N.m (50 kgf.cm, 43 in. lbf) . c. Remove the 2 clips and luggage compartment door inside handle cover.

Fig. 46: Locating Luggage Compartment Door Handle Mounting Clips (Inside Handle) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE: Tape the screwdriver tip before use.

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d. Using a screwdriver remove the luggage compartment door inside handle. 2. Remove door combination light : a. Disconnect the connector. b. Remove the nuts and rear combination lights. 3. Remove door lock cylinder : Remove the retainer and lock cylinder. ADJUSTMENT 1. Adjust luggage compartment door : a. For forward/rearward and left/right adjustments loosen the bolts. Torque: 6.9 N.m (70 kgf.cm, 61 in. lbf) b. For vertical adjustment of the front end of the door, increase or decrease the number of washers between the hinge and the door.

Fig. 47: Identifying Adjustment Directions Controlled By Luggage Compartment Door Mounting Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 2. Adjust door lock striker :

2002 EXTERIOR/INTERIOR TRIM Body - Corolla

a. Remove the rear floor finish plate by pulling. b. Remove the clips and the rear luggage trim. c. Loosen the bolts to adjust.

Fig. 48: Identifying Adjustment Directions Controlled By Luggage Compartment Door Lock Striker Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Torque: 4.9 N.m (50 kgf.cm, 43 in. lbf) REASSEMBLY Reassembly is in the reverse order of disassembly. See DISASSEMBLY . INSTALLATION Installation is in the reverse order of removal. See REMOVAL .

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FRONT WIPER AND WASHER

COMPONENTS

Fig. 49: Locating Front Wiper And Washer Components Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL 1. 2. 3. 4. Remove wiper arms . Remove hood to cowl top seal . Remove cowl louver . Remove wiper motor assembly : a. Disconnect the connector. b. Unfasten the 4 bolts and remove the wiper motor assembly.

2002 EXTERIOR/INTERIOR TRIM Body - Corolla

Fig. 50: Locating Wiper Motor Mounting Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 5. Remove wiper link assembly : Remove the 6 bolts and wiper link. 6. Remove window washer nozzle : a. Remove the hose from the nozzle. NOTE: Tape the screwdriver tip before use.

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Fig. 51: Unclipping Window Washer Nozzle Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Using a screwdriver, remove the nozzle. c. Employ the same manner described above to the other side. INSPECTION
Inspect Washer Nozzle

NOTE:

Letters of lists correspond to window washer fluid coverage areas identified in figures.

For USA, see Fig. 52 . For CANADA, see Fig. 53 .

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. a. While operating the washer, check that the washer fluid hits the windshield and the upsurge area within the shaded areas. USA

Fig. 52: Identifying Window Washer Fluid Coverage Areas (USA) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. A. B. C. D. E. F. G. H. I. Approx. 150 mm (5.91 in.) . Approx. 50 mm (1.97 In.) . Approx. 0-50 mm (0 - 5.91 in.) . Approx. 415 mm (16.34 in.) . Approx. 210 mm (8.28 in.) . Approx. 220 mm (8.66 in.) . Approx. 250 mm (9.84 in.) . Approx. 260 mm (10.24 in.) . Approx. 365 mm (14.37 in.) .

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CANADA

Fig. 53: Identifying Window Washer Fluid Coverage Areas (CANADA) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. A. Approx. 150 mm (5.91 in.) . B. Approx. 0-50 mm (0 - 5.91 in.) . C. Approx. 190 mm (7.48 in.) . D. Approx. 450 mm (17.72 in.) . E. Approx. 165 mm (6.50 in.) . F. Approx. 465 mm (18.31 in.) . G. Approx. 210 mm (8.27 in.) . H. Approx. 80 mm (3.15 in.) . I. Approx. 55 mm (2.17 in.) . J. Approx. 300 mm (11.81 in.) . K. Approx. 490 mm (19.29 in.) . b. Check if the lower point where the washer fluid hits the windshield is within the range of the wiping pattern (the area of the glass which the wiper blades wipe).

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ADJUSTMENT
Adjust Washer Nozzle

Rotate the nozzle to adjust the fluid direction against the windshield. Tool Dimension A: USA: 0.7 - 0.75 mm (0.028 - 0.0295 in.) CANADA: 0.55 - 0.6 mm (0.0217 - 0.024 in.) Tool Dimension B: . 2.0 - 2.5 mm (0.079 - 0.098 in.)

Fig. 54: Identifying Nozzle Adjustment Tool Dimensions For A & B Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSTALLATION 1. Install window washer nozzles . 2. Install wiper link assembly : Install the wiper link with the 6 bolts. Torque: 5.4 N.m (55 kgf.cm, 48 in. lbf) . 3. Install wiper motor assembly :

2002 EXTERIOR/INTERIOR TRIM Body - Corolla

a. Fasten the 4 bolts and install the wiper motor assembly. Torque: 5.4 N.m (55 kgf.cm, 48 in. lbf) . b. Connect the connector. 4. Install cowl louver . 5. Install hood to cowl top seal . 6. Install wiper arms : a. Install the wiper arms and tighten nuts by hand. Operate the wipers once and turn the wiper switch OFF. b. Adjust the installation positions of the wiper arms to the proper positioin.

Fig. 55: Identifying Proper Position Of Wiper Arms Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. A: 25.0 + 15.0 mm (0.984 + 0.591 in.) . c. Torque the nuts. Torque: 20 N.m (205 kgf.cm, 15 ft.lbf) .

BODY OUTSIDE MOULDING

COMPONENTS

2002 EXTERIOR/INTERIOR TRIM Body - Corolla

Fig. 56: Identifying Body Outside Moulding Components Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL NOTE: Do not heat moulding excessively.

1. Heat moulding : Using a heat light, heat the moulding to 40 - 60C (104 - 140F). CAUTION:

If reusing the moulding, take care not to damage the moulding. Do not damage the body.

2. Remove moulding : a. Tie both piano wire ends to a wooden block or a similar object. b. Cut the adhesive tape by pulling the piano wire.

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Fig. 57: Identifying Molding Removal Procedure Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Remove the moulding. INSTALLATION 1. Clean body mounting surface : NOTE: Do not heat body excessively.

a. Using a heat light, heat the body mounting surface to 40 -60C(104-140F). b. Remove protective tape from the body. c. Wipe off stains with cleaner. 2. Clean moulding (if reusing the moulding). NOTE: Do not heat moulding excessively.

a. Using a heat light, heat the moulding to 20 - 30C (68 -86F). b. Remove the adhesive tape from the moulding.

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c. Wipe off stains with cleaner. d. Apply a new adhesive tape to moulding.

Fig. 58: Identifying Adhesive Tape Application Points Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 3. Install moulding :

Fig. 59: Installing Moulding Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE: Do not heat moulding excessively.

a. Using a heat light, heat the body and moulding. Body: 40 - 60C (104 - 140F)

2002 EXTERIOR/INTERIOR TRIM Body - Corolla

Moulding: 20 - 30C (68 - 86F) NOTE:

When the moulding release sheet is removed, make sure that no dirt or dust can get onto the uncoated area. Do not apply excessive force onto the moulding, but steady pressure with your thumbs.

b. Lift moulding release sheet from the face of moulding.

ROOF DRIP SIDE FINISH MOULDING

COMPONENTS

Fig. 60: Identifying Roof Drip Side Finish Moulding Components Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL 1. Remove roof drip side finish moulding : Using SST, pull off the roof drip moulding from the front ends. SST 09806-30010

2002 EXTERIOR/INTERIOR TRIM Body - Corolla

Fig. 61: Removing & Exploded View Of Roof Drip Side Finish Moulding Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 2. Remove rear roof drip side finish moulding :

2002 EXTERIOR/INTERIOR TRIM Body - Corolla

Fig. 62: Locating Rear Roof Drip Side Finish Moulding Clips Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Using a clip remover, remove the moulding. INSTALLATION 1. Install rear roof drip side finish moulding . 2. Install roof drip side finish moulding : Attach the upper edge of the moulding to the body flange. Tap on the moulding by hand.

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Fig. 63: Installing Roof Drip Side Finish Moulding Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

ROCKER PANEL MOULDING

COMPONENTS

2002 EXTERIOR/INTERIOR TRIM Body - Corolla

Fig. 64: Identifying Rocker Panel Moulding Components Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL
Remove Rocker Panel Moulding

a. Remove the 2 screws and 6 clips.

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Fig. 65: Locating Rocker Panel Moulding Clips & Screws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE: Tape the screwdriver tip before use.

b. Using a screwdriver, remove the rocker panel moulding. INSTALLATION Installation is in the reverse order of removal. See REMOVAL .

WINDSHIELD
COMPONENTS

2002 EXTERIOR/INTERIOR TRIM Body - Corolla

Fig. 66: Identifying Windshield Components Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL 1. 2. 3. 4. Remove inner rear view mirror . Remove sun visors and holders . W/Sliding roof, remove map light . Remove front pillar garnish : a. Pry out clips by your hand.

2002 EXTERIOR/INTERIOR TRIM Body - Corolla

Fig. 67: Locating Front Pillar Garnish Clips Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Pull the garnish upward to remove it. c. Employ the same manner described above to the other side. Remove wiper arms . Remove hood to cowl top seal . Remove cowl louver . Remove assist grip . W/Sliding roof, remove sliding roof opening trim . Remove roof headlining front side . CAUTION: Do not damage the body with the knife.

5. 6. 7. 8. 9. 10.

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Fig. 68: Identifying Windshield Moulding Cut Line Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 11. Remove windshield moulding : Using a knife, cut off the moulding. CAUTION: When separating the glass, be careful not to damage the paint and interior and exterior ornaments. To prevent scratching the safety pad when removing the windshield, place a plastic sheet between the piano wire and safety pad. 12. Remove windshield glass : a. Push piano wire through between the body and glass from the interior.

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Fig. 69: Using Piano Wire To Separate Windshield From Vehicle (1 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE: Apply adhesive tape to the outer surface to keep the surface from being scratched.

b. Tie both wire ends to a wooden block or a similar object. NOTE: Leave as much of the adhesive on the body as possible when removing the glass.

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Fig. 70: Using Piano Wire To Separate Windshield From Vehicle (2 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Cut the adhesive by pulling the piano wire around it. d. Remove the glass. INSTALLATION 1. Clean and shape contact surface of body : a. Using a knife, cut away any rough areas on the body. NOTE: Leave as much of the adhesive on the body as possible.

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Fig. 71: Reshaping Adhesive Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE: Even if all the adhesive has been removed, clean the body.

b. Clean the cutting surface of the adhesive with a shop rag saturated in cleaner. 2. Replace stopper : a. Remove the damaged stopper. CAUTION: Be careful not to damage the body.

b. Cut off the old adhesive around the stopper installation area. c. Clean the installation area. d. Install a new stopper onto the glass.

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Fig. 72: Locating Windshield Stoppers & Identifying Stopper Dimensions Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 3. Clean removed glass : a. Using a scraper, remove the adhesive sticking to the glass.

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Fig. 73: Identifying Glass Cleaning Techniques Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Clean the glass with cleaner. NOTE: Do not touch the glass after cleaning it.

4. Replace dam : a. Remove the damaged dam. b. Clean the installation area. c. Install a new dam with double-stick tape. See Fig. 74 . NOTE: Do not touch the glass face after cleaning it.

A. 7.0 mm (0.276 in.) B. 16.3 mm (0.642 in.)

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Fig. 74: Identifying Application Points & Dimensions Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 5. Position glass : a. Place glass in the correct position.

2002 EXTERIOR/INTERIOR TRIM Body - Corolla

Fig. 75: Placing Reference Marks & Inspecting Windshield Placement Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Cheek that all contacting parts of the glass rim are perfectly even. c. Place reference marks between the glass and body. d. Remove the glass. NOTE: Do not touch the glass face after cleaning it.

6. Clean contact surface of glass : Using a cleaner, clean the contact surface which black-colored area around the entire glass rim. 7. Coat contact surface of body with primer "M" : Using a brush, coat the contact surface on the body with Primer M. NOTE:

Let the primer coating dry for 3 minutes or more. Do not coat Primer M to the adhesive. Do not keep any of the opened Primer "M" for later use.

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Fig. 76: Identifying Correct Application Of Primer "M" Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 8. Coat contact surface of glass with primer "G" : a. Using a brush or a sponge, coat the edge of the glass and the contact surface with Primer G. b. Before the primer dries, wipe it off with a clean shop rag. NOTE:

Let the primer coating dry for 3 minutes or more. Do not keep any of the opened Primer G for later use.

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Fig. 77: Identifying Correct Application Of Primer "G" Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 9. Apply adhesive : NOTE: After cutting off the tip, use all adhesive within the time described in the table.

Fig. 78: Ambient Temperature To Time Of Adhesive Use Table Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. a. Cut off the tip of the cartridge nozzle. Adhesive:

2002 EXTERIOR/INTERIOR TRIM Body - Corolla

Part No. 08850-00801 or equivalent b. Load the cartridge into the sealer gun. c. Coat the glass with adhesive as shown. A. 12.5 mm (0.492 in.) B. 8.0 mm (0.315 in.)

Fig. 79: Identifying Proper Glass Adhesive Application & Illustration Of Dimensions A & B Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 10. Install glass : NOTE: Confirm that the dam is attached to the body panel as shown. See Fig. 80 .

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Fig. 80: Identifying Proper Attachment Of Dam Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. a. Position the glass so that the reference marks are lined up, and press in gently along the rim.

Fig. 81: Realigning Reference Marks Placed On Windshield Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

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b. Using a spatula, apply adhesive on the glass rim. c. Use a scraper to remove any excessive or protruding adhesive.

Fig. 82: Scraping Excessive/Protruding Adhesive Off Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. d. Hold the glass in place securely with a protective tape or equivalent until the adhesive hardens. NOTE: Take care not to drive the vehicle during the time described in Fig. 83 .

Fig. 83: Windshield Installation To Safe Vehicle Operation Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 11. Inspect for leak and repair : a. Do a leak test after the hardening time has elapsed.

2002 EXTERIOR/INTERIOR TRIM Body - Corolla

b. Seal any leak with sealant. Sealant: Part No. 08833-00030 or equivalent 12. Apply adhesive at moulding installation area : Coat the glass with adhesive at the moulding installation area.

Fig. 84: Applying Moulding Adhesive Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Part No. 08833-00030 or equivalent 13. Install windshield moulding : Place a new moulding onto the body and tap it by hand.

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Fig. 85: Identifying Correct Installation Of Windshield Moulding Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 14. 15. 16. 17. 18. 19. Install roof headlining front side . W/Sliding roof, Install sliding roof opening trim Install assist grip . Install cowl louver . Install hood to cowl top seal . Install wiper arms : a. Install the wiper arms and tighten nuts by hand. Operate the wipers once and turn the wiper switch OFF. b. Adjust the installation positions of the wiper arms to the proper positions.

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Fig. 86: Identifying Proper Position Of Wiper Arms Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. A: 25.0 + 15.0 mm (0.984 + 0.591 in.) c. Torque the nuts. Torque: 20 N.m (205 kgf.cm, 15 ft.lbf) 20. 21. 22. 23. Install front pillar garnishes . W/Sliding roof, install map light Install sun visors and holders . Install inner rear view mirror .

BACK WINDOW GLASS

COMPONENTS

2002 EXTERIOR/INTERIOR TRIM Body - Corolla

Fig. 87: Identifying Back Window Glass Components Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL 1. Remove rear seat . See REMOVAL . 2. Remove high-mounted stop light . a. Push on the both sides of the cover to release the claws by your hand and remove the cover.

2002 EXTERIOR/INTERIOR TRIM Body - Corolla

Fig. 88: Locating High-Mounted Stop Light Clips & Identifying Removal Direction Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the stop light, then disconnect the connector. 3. Remove roof side inner garnish : a. Using a screwdriver, pry loose and remove the garnish. NOTE: Tape the screwdriver tip before use.

2002 EXTERIOR/INTERIOR TRIM Body - Corolla

Fig. 89: Locating Roof Side Inner Garnish Clips Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Employ the same manner described above to the other side. 4. Remove tether anchor : a. Using a screwdriver, remove the CRS tether anchor cover. NOTE: Tape the screwdriver tip before use.

b. Remove the tether anchor by loosening the bolt. c. Employ the same manner described above to the other sides. 5. Remove package tray trip . 6. Disconnect defogger wire connectors . NOTE: Do not damage the body with the knife.

2002 EXTERIOR/INTERIOR TRIM Body - Corolla

Fig. 90: Identifying Back Window Moulding Cut Line Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 7. Remove back window moulding . Using a knife, cut off the moulding.

2002 EXTERIOR/INTERIOR TRIM Body - Corolla

8. Remove back window glass : Remove the glass in the same way as windshield. See REMOVAL . INSTALLATION During back glass installation, the procedures follow those for windshield installation and are marked with references to the windshield installation steps used in the windshield installation procedure. Refer to INSTALLATION , and install the back window glass by the following operations. 1. Clean and shape contact surface of body . 2. Replace stopper . Refer to step 2 under WINDSHIELD INSTALLATION. a. Remove the damaged stoppers. b. Cut off the old adhesive around the stopper installation area. c. Clean the installation area. d. Install new stoppers on the glass.

Fig. 91: Locating Stoppers Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 3. Clean removed glass . Refer to step 3 under WINDSHIELD INSTALLATION. 4. Clean contact surface of glass . Refer to step 6 under WINDSHIELD INSTALLATION. 5. Coat contact surface of body with primer "M" . Refer to step 7 under WINDSHIELD INSTALLATION.

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6. Coat contact surface of glass with primer "G" . Refer to step8 under WINDSHIELD INSTALLATION. 7. Apply adhesive . Refer to step 9 under WINDSHIELD INSTALLATION. 8. Install back window glass . Refer to step 10 under WINDSHIELD INSTALLATION. 9. Inspect for leak and repair . a. Do a leak test after the hardening time has elapsed. b. Seal any leak with sealant. Refer to step 11 under WINDSHIELD INSTALLATION. Sealant: Part No. 08833-00030 or equivalent 10. Apply adhesive at moulding installation area . Refer to step 12 under WINDSHIELD INSTALLATION. 11. Install back window moulding . Refer to step 13 under WINDSHIELD INSTALLATION. 12. Connect defogger wire connectors . 13. Install package tray trim . 14. Install tether anchor . a. Install the tether anchor by tightening the bolt. b. Install the CRS tether anchor cover to the tether anchor. c. Employ the same manner described above to the other sides. 15. Install roof side inner garnishes : 16. W/High-mounted stop light, install high-mounted stop light

Fig. 92: Locating High-Mounted Stop Light Clips & Identifying Removal Direction Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

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a. Connect the connector, then install the stop light. b. Push on both sides of the cover to engage the claws by hand and install the cover. 17. Install rear seat. See INSTALLATION .

SLIDING ROOF
ON-VEHICLE INSPECTION
Inspect Sliding Roof Glass Alignment

Fig. 93: Identifying Correct Sliding Roof Alignment Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. a. Start the engine and check the operation time of the sliding roof. Operation time: Approx. 6 sec. b. Check for abnormal noise or binding during operation. c. With the sliding roof fully closed, check for water leakage. d. Check for a difference in level between the sliding roof weatherstrip and roof panel. Except rear end: 0 +/- 1.5 mm (0 +/- 0.059 in.) Rear end:

2002 EXTERIOR/INTERIOR TRIM Body - Corolla

0 + 1.5 mm (0 + 0.059 in.) 0-1.0 mm (0 - 0.039 in.) COMPONENTS

Fig. 94: Identifying Sliding Roof Components Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL

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1. Remove roof headlining. See REMOVAL . 2. Remove sliding roof glass assembly : a. Using a torx wrench, remove the 4 screws. b. Pull the glass upward to remove it. NOTE: At the time of installation, if the sliding roof position and drive gear full close position are not matched, the sliding roof does not operate normally. Remove the drive gear with the sliding roof fully closed.

NOTE:

3. Remove drive gear : a. Disconnect the connector. b. Remove the 3 bolts and drive gear.

Fig. 95: Locating Drive Gear & Mounting Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Remove the screw and cam plate cover. d. Turn the drive gear to align the point marks.

2002 EXTERIOR/INTERIOR TRIM Body - Corolla

2002 EXTERIOR/INTERIOR TRIM Body - Corolla

Fig. 96: Aligning Point Marks Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. e. Install the cam plate cover and screw. 4. Remove sliding roof housing : a. Disconnect the 4 drain hoses from the housing. b. Remove the 8 torx screws and 4 brackets.

Fig. 97: Locating Brackets, Torx Screws & Bolts Called Out In Step 4 Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Remove the 6 nuts, then remove the housing. DISASSEMBLY 1. Remove sliding roof panel stopper : Remove the 2 screws and 2 stoppers. 2. Remove sunshade trim :

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Fig. 98: Locating Sunshade Trim Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 3. Remove rear roof drip channel : Remove the rear roof drip channel.

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Fig. 99: Removing Rear Roof Drip Channel Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE: At the time of reassembly, please refer to following items.

Adjust the drive cable to a closed and tilted down position. Slide the cable forward or backward to align the 2 marks.

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Fig. 100: Locating Cable Alignment Marks Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Slide the cable to the forefront with your hand.

4. Remove drive cable : a. Remove the screw and guide rail stopper.

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Fig. 101: Drive Cable Removal Procedure Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Slide the drive cable rearward, then remove it. 5. Remove roof window deflector panel : 6. Remove guide block : Remove the 2 screws and guide block.

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Fig. 102: Locating Guide Block Mounting Screws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 7. Remove sliding roof housing : Remove the 6 screws and sliding roof housing.

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Fig. 103: Locating Sliding Roof Housing Mounting Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ADJUSTMENT 1. To adjust forward or rearward : a. Using a torx wrench, loosen the sliding roof glass installation screws. b. Adjust the sliding roof glass forward and rearward. 2. Difference in left and right clearance: To adjust clearance : a. When the front or rear alignment is not correct, remove the drive gear and sliding roof glass, then adjust the drive rail. NOTE: Remove the drive gear with sliding roof fully closed.

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Fig. 104: Identifying Misalignment & Proper Alignment Of Sliding Roof Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Adjust by sliding the cable forward or rearward to align the 2 marks.

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Fig. 105: Locating Cable Alignment Marks Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Install the drive gear and sliding roof glass. REASSEMBLY Reassembly is in the reverse order of disassembly. See DISASSEMBLY . INSTALLATION Installation is in the reverse order of removal. See REMOVAL .

INSTRUMENT PANEL
COMPONENTS

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Fig. 106: Locating Instrument Panel Components (1 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

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Fig. 107: Locating Instrument Panel Components (2 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE: Screw shapes and sizes are indicated in Fig. 108 . The codes (A - H) correspond to those indicated in Fig. 106 and Fig. 107 .

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Fig. 108: Screw Identification & Sizing Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL 1. Remove front door scuff plates . 2. Remove cowl side trims . 3. Remove front pillar garnish : a. Pry out clips by your hand.

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Fig. 109: Locating Front Pillar Garnish Clips Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Pull the garnish upward to remove it. c. Employ the same manner described above to the other side. 4. Remove steering wheel . See STEERING COLUMN . 5. Remove lower finish panel : a. Remove the 2 bolts and panel.

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Fig. 110: Locating Lower Finish Panel Mounting Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disconnect the hood lock control cable. 6. Remove lower insert : Remove the 2 bolts and lower insert. 7. Remove cluster finish panel : a. Remove the 2 screws. NOTE: Tape the screwdriver tip before use.

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Fig. 111: Locating Cluster Finish Panel Clips & Mounting Screws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Using a screwdriver, remove the cluster finish panel. Remove steering column cover . See STEERING COLUMN . Remove combination switch . Remove No. 2 heater to register duct . Remove combination meter . Remove steering column assembly . See STEERING COLUMN . Remove lower panel : Remove the 2 bolts, 3 screws and lower panel.

8. 9. 10. 11. 12. 13.

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Fig. 112: Locating Lower Panel Mounting Bolts & Screws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 14. Disconnect AIRBAG connector : CAUTION: When handling the AIRBAG connector, take care not to damage the AIRBAG wire harness. a. Remove the AIRBAG connector from the front passenger AIRBAG assembly. b. Disconnect the AIRBAG connector.

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Fig. 113: locating AIRBAG connector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 15. Remove front passenger AIRBAG assembly : NOTE: At the time of installation, please refer to the following items:

Make sure that the front passenger AIRBAG assembly is installed to the specified torque. If the front passenger AIRBAG assembly has been dropped, or there are cracks, dents or other defects in the case or connector, replace the front passenger - AIRBAG assembly with a new one. When installing the front passenger AIRBAG assembly, take care that the wiring does not interfere with other parts and is not pinched between other parts.

a. Remove the 2 bolts and 2 nuts. Torque: Bolt: 20 N.m (205 kgf.cm, 15 ft.lbf) WARNING:

Do not store the front passenger AIRBAG assembly with the AIRBAG deployment side facing down. Never disassemble the front passenger AIRBAG

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assembly.

Fig. 114: Locating Front Passenger AIRBAG & Mounting Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the front passenger AIRBAG assembly from the instrument panel. 16. Remove lower LH panel : Remove the bolt and panel. 17. Remove lower RH panel : Remove the bolt and panel. 18. 19. 20. 21. M/T, remove shifting hole knob . M/T, remove shifting hole cover . A/T, remove shifting hole bezel . Remove rear console box . Remove the 2 bolts, 2 screws and rear console box. NOTE: Tape the screwdriver tip before use.

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22. Remove center lower cluster finish panel : Using a screwdriver, remove the center lower cluster finish panel, then disconnect the connector. 23. Remove stereo opening cover . 24. Remove lower center finish panel : Remove the 2 screws and lower center finish panel.

Fig. 115: Locating Lower Center Finish Panel Clips Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 25. Remove A/C control panel. See REMOVAL . 26. Remove center cluster finish panel : NOTE: Tape the screwdriver tip before use.

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Fig. 116: Locating Center Cluster Finish Panel Clips Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. a. Using a screwdriver, remove the center cluster finish panel. b. Remove the radio assembly. 27. Remove instrument panel : a. Disconnect the connectors. b. Remove the 4 screws and instrument panel.

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Fig. 117: Locating Instrument Panel Mounting Screws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 28. Remove heater to register duct : Remove the screw and heater to register duct. 29. Remove lower defroster nozzle . 30. Remove No. 1 brace : Remove the bolt, 2 nuts and No. 1 brace. 31. Remove No. 2 brace : Remove the bolt, nut and No. 2 brace. 32. Remove reinforcement : Remove the 3 bolts, 4 nuts and reinforcement. 33. Remove lower instrument panel cowl brace : Remove the bolt, nut and lower instrument panel cowl brace.

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DISASSEMBLY 1. Remove defroster nozzle : Remove the 3 screws and defroster nozzle. 2. Remove No. 1 heater to register duct : Remove the 2 screws and No. 1 heater to register duct. 3. Remove cluster finish panel sub-assembly . 4. Remove center bracket : Remove the 3 screws and center bracket. 5. Remove meter mounting bracket : Remove the screw and meter mounting bracket. 6. Remove safety pad : Remove the 8 screws and safety pad. 7. Remove wire harness . REASSEMBLY Reassembly is in the reverse order of disassembly. See DISASSEMBLY . INSTALLATION Installation is in the reverse order of removal. See REMOVAL .

ROOF HEADLINING
COMPONENTS

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Fig. 118: Identifying Roof Headlining Components Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL 1. 2. 3. 4. 5. Remove rear seat . See REMOVAL . Remove inner rear view mirror . Remove front door scuff plates . Remove cowl side trims . Remove center pillar lower garnishes .

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6. 7. 8. 9.

Remove rear door scuff plates . Remove front door opening trims . Remove rear door opening trims . Remove front pillar garnish . a. Pry out clips by your hand.

Fig. 119: Locating Front Pillar Garnish Clips Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Pull the garnish upward to remove it. c. Employ the same manner described above to the other side. 10. Remove center pillar upper garnish : a. Remove the front seat outer belt shoulder anchor. Torque: 41 N.m (420 kgf.cm, 30 ft.lbf) b. Remove the center pillar upper garnish.

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Fig. 120: Locating Center Pillar Upper Garnish Clip Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Employ the same manner described above to the other side. 11. W/High-mounted stop light, remove high-mounted stop light . a. Push on the both sides of the cover to release the claws by your hand and remove the cover.

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Fig. 121: Locating High-Mounted Stop Light Clips & Identifying Removal Direction Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the stop light, then disconnect the connector. 12. Remove roof side inner garnish : NOTE: Tape the screwdriver tip before use.

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Fig. 122: Locating Roof Side Inner Garnish Clips Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. a. Using a screwdriver, pry loose and remove the garnish. b. Employ the same manner described above to the other side. 13. Remove tether anchor : a. Using a screwdriver, remove the CRS tether anchor cover. NOTE: Tape the screwdriver tip before use.

b. Remove the tether anchor by loosening the bolt. c. Employ the same manner described above to the other sides. 14. Remove package tray trim . 15. Remove room light : a. Using a screwdriver, remove the room light cover. NOTE: Tape the screwdriver tip before use.

b. Remove the 3 screws, then disconnect the connector.

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Fig. 123: Locating Room Light, Cover & Mounting Screws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 16. 17. 18. 19. W/Sliding roof, remove map light assembly . W/Sliding roof, remove sliding roof opening trim . Remove sun visors and holders . Remove assist grips .

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20. Remove roof headlining : a. Remove the 3 clips from the roof panel rear end. b. Remove the headlining. c. Bring out the headlining.

Fig. 124: Locating Roof Panel Clips (Rear End) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSTALLATION Installation is in the reverse order of removal. See REMOVAL .

FRONT SEAT
COMPONENTS

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Fig. 125: Locating Front Seat Components Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL Remove front seat : a. Using a screwdriver, remove the seat track covers. NOTE: Tape the screwdriver tip before use.

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b. Remove the 4 bolts. c. W/Side AIRBAG assembly, disconnect the connector. d. Remove the front seat. NOTE: Be careful not to damage the body.

DISASSEMBLY 1. 2. 3. 4. Remove headrest . Remove reclining adjuster release handle . Remove front seat cushion shield . Remove inner front seat cushion cover . Remove the screw and inner front seat cushion cover. 5. Remove front seat inner belt . Remove the bolt and front seat inner belt. 6. Remove seatback assembly . a. W/Side AIRBAG assembly, remove side AIRBAG wire harness from wire harness protector.

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Fig. 126: Locating Side AIRBAG Wire Harness Protector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the hog rings. c. Remove the 4 bolts and seatback assembly. 7. Remove seatback cover : a. W/Side AIRBAG assembly, Remove the hook from the seatback frame.

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Fig. 127: Locating Seatback Frame Hook (W/Side AIRBAG) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the headrest supports. c. Remove the seatback frame from the seatback cover with pad. d. Remove the seatback cover from the seatback pad. 8. Remove seat cushion assembly Remove the 4 bolts and seat cushion assembly from the seat adjuster. 9. Remove seat cushion cover : a. Remove the hog rings and seat cushion frame. b. Remove the hog rings and seat cushion cover from the seat cushion pad. 10. Remove reclining connecting pipe : Remove the reclining connecting pipe. 11. Remove seat track handle : Remove the seat track handle. INSPECTION

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Inspect reclining lock position and sliding lock position slipping off NOTE: When the reclining lock positions slip off, disassemble the seat to adjust the position.

a. When reclining the seat, inspect that the outer and inner recliners are released at the same time. NOTE: When sliding lock positions slip off, loosen the bolts to adjust the position.

b. When sliding the seat, inspect that the outer and inner tracks are locked at the same time. REASSEMBLY 1. Install seat track handle : Install the seat track handle. NOTE: When installing the connecting pipe with raising up the adjusters, the lock positions adjusted in 2-(a) step slip off then lock error will occur.

2. Install reclining connecting pipe : a. Adjust the reclining lock positions of the seat adjusters. b. Slide the seat adjusters to the most front position. c. Place the adjusters on a spacer to adjust the seat rails in parallel and install the connecting pipe.

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Fig. 128: Identifying Spacer Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 3. Install seat cushion cover : a. Install the seat cushion cover with new hog rings to seat cushion pad. NOTE: Install the hog rings to prevent wrinkles as least as possible.

b. Install the seat cushion cover with pad to the seat cushion frame with new hog rings. NOTE: Tighten the 4 bolts temporarily, then from the bolts on the rear side tighten them completely.

4. Install seat cushion assembly : Install the seat cushion assembly with the 4 bolts to the seat adjuster. Torque: 21 N.m (210 kgf.cm, 15 ft.lbf) 5. Install seatback cover : a. Install the seatback cover with new hog rings to the seat-back pad. b. Install the seatback cover with pad to the seatback frame with new hog rings.

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c. Install the headrest supports. d. W/Side AIRBAG assembly, hang the hook onto the seatback frame.

Fig. 129: Locating Seatback Frame Hook (W/Side Airbag) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. CAUTION: Take care to hung the hook securely. Otherwise the seat cover slides, it might cause incorrect deploying. 6. Install seatback assembly : a. Install the seatback assembly with 4 bolts. NOTE: Tighten the 4 bolts temporarily, then from the bolt on the front right side tighten them completely.

Torque: 43 N.m (440 kgf.cm, 32 ft.lbf) NOTE: Install the hog rings to prevent wrinkles as least as possible.

b. Install new hog rings. c. W/Side AIRBAG assembly, securely fix the side AIRBAG wire harness to seat cushion with

2002 EXTERIOR/INTERIOR TRIM Body - Corolla

the wire harness protector.

Fig. 130: Locating Side AIRBAG Wire Harness Protector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 7. Install front seat inner belt : Install the front seat inner belt with the bolt. Torque: 41 N.m (420 kgf.cm, 30 ft.lbf) 8. Install inner front seat cushion cover : Install the inner front seat cushion cover with the screw. 9. Install front seat cushion shield . 10. Install reclining adjuster release handle . 11. Install headrest . INSTALLATION Install front seat :

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a. Slide the front seat to the most front position. NOTE: NOTE: Make sure that seat adjuster locks. If holding the seat track handle, the adjusted most front positions slip off.

b. Without holding the seat track handle, mount the seat to the vehicle. c. Tighten the bolts on the rear side temporarily, from the bolt on the inner side tighten them completely. Torque: 37 N.m (375 kgf.cm, 27 ft.lbf) d. Slide the seat to the most rear position to install the bolts on the front side. Torque: 37 N.m (375 kgf.cm, 27 ft.lbf) e. W/Side AIRBAG assembly, connect the connector. f. Install the seat track covers.

REAR SEAT (SPLIT TYPE)

COMPONENTS

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Fig. 131: Locating Split Type Rear Seat Components (1 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

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Fig. 132: Locating Split Type Rear Seat Components (2 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL

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1. Remove seat cushion assembly : a. Remove the seat cushion assembly. b. Remove the 2 lock hooks. 2. Remove LH seatback assembly : a. Release lock to lean the seatback to front. b. Remove the 2 bolts and the LH seatback assembly. 3. W/CRS, Remove child restraint seat a. Remove the child restraint seat cover. b. Remove the 4 bolts. c. Remove the child restraint seat. 4. W/O CRS, remove RH seatback assembly a. Release lock to lean the seatback to front. b. Remove the 2 bolts and the RH seatback assembly. 5. W/CRS, remove RH seatback assembly Remove the 3 bolts and the RH seatback assembly. 6. Remove seatback hinge : a. Remove the 2 bolts and LH seatback hinge. b. Remove the 2 bolts and center seatback hinge. c. Remove the 2 bolts and RH seatback hinge. DISASSEMBLY 1. Remove seat cushion cover : Remove the hog rings and seat cushion cover from the seat cushion pad. 2. Turn over seatback cover : Remove the clips, and turn over the seatback cover. Remove headrest . Remove headrest supports . Remove seatback lock knob . Remove seatback lock knob cover . Remove seatback cover : a. Remove the hog rings and seatback frame from the seatback cover with pad. b. Remove the hog rings and seatback cover from the seatback pad. 8. Remove seatback lock : a. Remove the rear lock control cable. b. Remove the 2 bolts and rear seatback lock control. REASSEMBLY 3. 4. 5. 6. 7.

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Reassembly is in the reverse order of disassembly. See DISASSEMBLY . INSTALLATION Installation is in the reverse order of removal. See REMOVAL .

REAR SEAT (FIXED TYPE)

COMPONENTS

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Fig. 133: Locating Fixed Type Rear Seat Components Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL 1. Remove seat cushion assembly : a. Remove the seat cushion assembly. NOTE: Remove the rear seat inner with center belt from seat cushion slit to remove the seat cushion.

b. Remove the 2 lock hooks. 2. Remove seatback assembly : Remove the 3 bolts and the seatback assembly. DISASSEMBLY 1. Remove seat cushion cover : Remove the hog rings and seat cushion cover from the seat cushion pad. 2. Remove seatback cover : a. W/Headrest, remove the 2 headrests. b. W/Headrest, remove the 4 headrest supports. c. Remove the hog rings and seatback cover from the seatback pad. REASSEMBLY Reassembly is in the reverse order of disassembly. See DISASSEMBLY . INSTALLATION Installation as In the reverse order of removal. See REMOVAL .

SEAT BELT
COMPONENTS

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Fig. 134: Locating Seat Belt Components (1 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

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Fig. 135: Locating Seat Belt Components (2 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSPECTION CAUTION: Replace the seat belt assembly (outer belt, inner belt, bolts, nuts) if it

2002 EXTERIOR/INTERIOR TRIM Body - Corolla

has been used in a severe impact. The entire assembly should be replaced even if damage is not obvious. 1. Except manual type, Running test (in safe area) a. Fasten the front seat belts. b. Drive the car at 10 mph (16 km/h) and slam on the brakes. Check that the belt locks and cannot be extended at this time. CAUTION: Conduct this test in a safe area. If the belt does not lock, remove the belt mechanism assembly and conduct the following static check. Also, whenever installing a new belt assembly, verify the proper operation before installation. 2. Driver's seat belt (ELR): Static test a. Make sure that the belt locks when pulled out quickly. b. Remove the locking retractor assembly. c. Tilt the retractor slowly. d. Make sure that the belt can be pulled out at a tilt of 15 degrees or less, and cannot be pulled out over 45 degrees of tilt.

Fig. 136: Measuring Seat Belt Tilt Angle

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Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. If a problem is found, replace the assembly. NOTE: Ensure that more than 300 mm (11.81 in.) of belt is extracted with installed on the vehicle. If a problem is found, replace the assembly. 3. Except driver's seat belt (ALR/ELR): Static Test a. Make sure that the belt locks when pulled out quickly. NOTE: Ensure that more than 200 mm (7.87 in.) of rear seat belt is retracted with installed on the vehicle.

b. Remove the locking retractor assembly. c. Pull out the whole belt and measure the length of the whole belt. Then retract the belt slightly and pull it out again. d. Make sure that the belt cannot be extended further. If a problem is found, replace the assembly. e. Retract the whole belt, then pull out the belt until 200 mm (7.87 in.) of belt remains retracted.

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Fig. 137: Measuring Seat Belt Retraction Length Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. f. Tilt the retractor slowly. g. Make sure that the belt can be pulled out at a tilt of 15 degrees or less, and cannot be pulled out at over 45 degrees of tilt.

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Fig. 138: Measuring Seat Belt Tilt Angle Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

SEAT BELT PRETENSIONER

REMOVAL NOTE:

If the wiring connector of the seat belt pretensioner is disconnected with the ignition switch at ON or ACC, diagnostic trouble codes will be recorded. Never use seat belt pretensioner from another vehicle. When replacing parts, replace them with new parts.

1. Remove front door scuff plate 2. Remove center pillar lower garnish 3. Remove front seat outer belt a. Remove the bolt and front seat outer belt floor anchor. b. Using a screwdriver, remove the shoulder anchor caps. NOTE: Tape the screwdriver tip before use.

c. Remove the bolt and front seat outer belt shoulder anchor.

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Fig. 139: Locating Outer Belt Shoulder Anchor (Front Seat) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 4. Remove retractor of front seat outer belt : CAUTION: Never disassemble the front seat outer belt.

NOTE:

When removing the front seat outer belt, take care not to pull the seat belt pretensioner wire harness.

a. LH side only:

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Disconnect the retractor switch connector. CAUTION: When removing the seat belt pretensioner, work must be started 90 seconds after the ignition switch is turned to the "LOCK" position and the negative (-) cable is disconnected from the battery.

Fig. 140: Locating Pretensioner Connector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disconnect the pretensioner connector. c. Remove the 2 bolts and retractor of the front seat outer belt. INSPECTION 1. Pretensioner is not activated a. Perform a diagnostic system check. See AIR BAG RESTRAINT SYSTEMS . b. Perform a visual check which includes the following items with the front seat outer belt removed from the vehicle. NOTE: For removal and installation of the front seat outer belt, see SEAT BELT . Be sure to follow the correct procedure.

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Fig. 141: Seat Belt Pretensioner Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Check for cuts and cracks in, or marked discoloration of the center pillar lower garnish. Check for cuts and cracks in wire harness, and for chipping in connectors. Check for deformation of the center pillar. 2. Pretensioner is activated :

2002 EXTERIOR/INTERIOR TRIM Body - Corolla

a. Perform a diagnostic system check. See AIR BAG RESTRAINT SYSTEMS . b. Perform a visual check which includes the following item with the front seat outer belt removed from the vehicle. Check for deformation of the center pillar.

Fig. 142: Identifying Center Pillar & Wire Harness Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Check for damage to the connector and wire harness.

DISPOSAL NOTE: When scrapping vehicle equipped with an SRS or disposing of a front seat outer belt (with seat belt pretensioner), always first deploy the AIRBAG in accordance with the procedure given in AIR BAG RESTRAINT SYSTEMS . If any abnormality occurs with the AIRBAG deployment or seat belt pretensioner activation, contact the SERVICE DEPARTMENT of TOYOTA MOTOR SALES, USA INC. When disposing of a front seat outer belt (with seat belt pretensioner) activated in a collision, follow the same procedure given in step 1 (c ).

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CAUTION:

Never dispose of front seat outer belt which has inactivated pretens The seat belt pretensioner produces a sizeable exploding sound wh activates, so perform the operation out-of-door and where it will not create a nuisance to nearby residents. When activating the seat belt pretensioner, always use the specified (SRS AIRBAG Deployment Tool). Perform the operation in a place a from electrical noise.

Fig. 143: Identifying SRS Deployment Tool Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. SST 09082-00700, 09082-00740

When activating a front seat outer belt (with seat belt pretensioner), perform the operation at least 10 m (33 ft) away from the front seat o belt. Use gloves and safety glasses when handling a front seat outer bel activated pretensioner. Always wash your hands with water after completing the operation. Do not apply water, etc. to a front seat outer belt with activated pretensioner.

1. Seat Belt Pretensioner Deployment When Scrapping Vehicle :

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NOTE:

Have a battery ready as the power source to activate the seat belt pretensioner.

Fig. 144: Powering SRS Deployment Tool Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. a. Check functioning of SST. SST 09082-00700, 09082-00740 CAUTION: When activating the seat belt pretensioner, always use the specified SST: SRS AIRBAG Deployment Tool.

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Fig. 145: Identifying SRS Deployment Tool Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 1. Connect the SST to battery. NOTE: Do not connect the yellow connector which will be connected with the seat belt pretensioner.

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Fig. 146: Powering SRS Deployment Tool Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Connect the red clip of the SST to the battery positive (+) terminal and the black clip to the battery negative (-) terminal. 2. Check functioning of SST. CAUTION: If the LED lights up when the activation switch is not being pressed, SST malfunction is probable, so definitely do not use the SST. Press the SST activation switch, and check the LED of the SST activation switch lights up.

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Fig. 147: Locating SRS Deployment Tool Activation Switch Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disconnect the pretensioner connector. 1. Remove the front door scuff plate. 2. Remove the center pillar lower garnish. 3. Disconnect the pretensioner connector.

2002 EXTERIOR/INTERIOR TRIM Body - Corolla

Fig. 148: Locating Pretensioner Connector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Install the SST. 1. Buckle the front seat belt and check that there is no looseness and slack in the front seat inner belt and front seat outer belt. CAUTION: To avoid damaging the SST connector and wire harness, do not lock secondary lock of the twin lock.

2002 EXTERIOR/INTERIOR TRIM Body - Corolla

Fig. 149: Connecting SST's To Seat Belt Pretensioner Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 2. Connect the 2 SSTs to each other, then connect them to the seat belt pretensioner. SST 09082-00700, 09082-00740 3. Move the SST to at least 10mm (33 ft) from the front of the vehicle. CAUTION: Take care not to damage the SST wire harness.

4. Close all the doors and windows of the vehicle. 5. Connect the SST red clip to the battery positive (-) terminal and the black clip to the negative (+) terminal. d. Activate seat belt pretensioner. 1. Confirm that no one is inside the vehicle or within 10 m (33 ft) area around the vehicle. NOTE: The seat belt pretensioner operates simultaneously as the LED of the SST activation switch lights up.

2. Press the SST activation switch and activate the seat belt pretensioner.

2002 EXTERIOR/INTERIOR TRIM Body - Corolla

e. Dispose of the front seat outer belt (with seat belt pretensioner).

Fig. 150: Measuring SRS Deployment Tool To Vehicle Distance Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. CAUTION:

The front seat outer belt is very hot when the seat belt pretensioner is activated, so leave it alone for at least 30 minutes after activation. Use gloves and safety glasses when handling a front seat outer belt with activated seat belt pretensioner. Always wash your hands with water after completing the operation. Do not apply water, etc. to a front seat outer belt with activated seat belt pretensioner.

NOTE:

When scrapping a vehicle, activate the seat belt pretensioner and scrap the vehicle with activated front seat outer belt still installed.

2. Activation when disposing of front seat outer belt only NOTE:

When disposing of the front seat outer belt (with seat belt pretensioner)

2002 EXTERIOR/INTERIOR TRIM Body - Corolla

only, never use the customer's vehicle to activate the seat belt pretensioner. Be sure to follow the procedure given below when activating the seat belt pretensioner.

NOTE:

Have a battery ready as the power source to activate the seat belt pretensioner.

a. Remove the front seat outer belt. See SEAT BELT . NOTE: Cut the belt near the seat belt retractor.

b. Check functioning of SST. See step 1-( ). SST 09082-00700, 09082-00740

Fig. 151: Powering SRS Deployment Tool Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 EXTERIOR/INTERIOR TRIM Body - Corolla

c. Install the SST. 1. Connect the 2 SSTs to each other, then connect them to the seat belt pretensioner. CAUTION: To avoid damaging the SST connector and wire harness, do not lock the secondary lock of the twin lock.

Fig. 152: Connecting SST's To Seat Belt Pretensioner Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. SST 09082-00700, 09082-00740 NOTE: Place the front seat outer belt. See Fig. 153 .

2002 EXTERIOR/INTERIOR TRIM Body - Corolla

Fig. 153: Placing Front Seat Outer Belt Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 2. Locate the front seat outer belt on the ground and cover it with the disc wheel with tire. NOTE: Take care not to damage the SST wire harness.

3. Move the SST to at least 10 m (33 ft) from the disc wheel. d. Activate the seat belt pretensioner. 1. Connect the SST red clip to the battery positive (+) terminal and black clip to the battery negative (-) terminal. 2. Check that no one is within 10 m (33 ft) area around the disc wheel.

2002 EXTERIOR/INTERIOR TRIM Body - Corolla

Fig. 154: Identifying Safety Distance SST To SRS Deployment Tool/Nearest Person Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE: The seat belt pretensioner operates simultaneously as the LED of the SST activation switch lights up.

3. Press the SST activation switch and activate the seat belt pretensioner. e. Dispose of the front seat outer belt (with seat belt pretensioner). CAUTION:

The front seat outer belt is very hot when the seat belt pretensioner is activated, so leave it alone for at least 30 minutes after activation. Use gloves and safety glasses when handling a front seat outer belt with activated seat belt pretensioner. Always wash your hands with water after completing the operation. Do not apply water, etc. to a front seat outer belt with activated seat belt pretensioner.

1. Remove the disc wheel and SST. 2. Place the front seat outer belt in a vinyl bag, tie the end tightly and dispose of it in the same way as other general parts.

2002 EXTERIOR/INTERIOR TRIM Body - Corolla

Fig. 155: Disposing Of Front Seat Outer Belt Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REPLACEMENT
Replace Requirements

2002 EXTERIOR/INTERIOR TRIM Body - Corolla

In the following cases, replace the seat belt pretensioner.

If the seat belt pretensioner has been activated. If the seat belt pretensioner has been found to be faulty in troubleshooting. If the front seat outer belt has been found to be faulty during the check in items 1-(b) or 2-(b). If the front seat outer belt has been dropped. CAUTION: For removal and installation of the seat belt pretensioner, see SEAT BELT PRETENSIONER and INSTALLATION . Be sure to follow the correct procedure.

INSTALLATION NOTE:

Never use seat belt pretensioner from another vehicle. When replacing parts, replace them with new parts. Make sure that the front seat outer belt is installed to the specified torque. If the front seat outer belt has been dropped, or there are cracks, dents or other defects in the case or connector, replace the front seat outer belt with a new one. When installing the front seat outer belt, take care that the wiring does not interfere with other parts and is not pinched between other parts.

1. Install retractor of front seat outer belt a. Install retractor of front seat outer belt with the 2 bolts. Torque: Upper bolt: 4.9 N.m (50 kgf.cm, 43 in. lbf) Lower bolt: 41 N.m (420 kgf.cm, 30 ft.lbf) b. Connect the pretensioner connector. See Fig. 156 .

2002 EXTERIOR/INTERIOR TRIM Body - Corolla

Fig. 156: Locating Pretensioner Connector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. LH side only: Connect the retractor switch connector. 2. Install front seat outer belt a. Install the front seat outer belt shoulder anchor with the bolt. Torque: 41 N.m (420 kgf.cm, 30 ft.lbf) b. Install the shoulder anchor cap. c. Install the front seat outer belt floor anchor with the bolt. Torque: 41 N.m (420 kgf.cm, 30 ft.lbf) . 3. Install center pillar lower garnish . 4. Install front door scuff plate .

2002 ACCESSORIES & EQUIPMENT Exterior Lights - Corolla

2002 ACCESSORIES & EQUIPMENT Exterior Lights - Corolla

FOG LIGHT SYSTEM

NOTE: For manufacturers precautions, see BODY, CAB CONTROL SYSTEMS . For circuit troubleshooting, see FOG LIGHT SYSTEM . For circuit wiring diagrams, see HEADLIGHTS .

LOCATION

2002 ACCESSORIES & EQUIPMENT Exterior Lights - Corolla

Fig. 1: Locating Fog Light System Components Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSPECTION 1. Inspect fog light switch continuity :

2002 ACCESSORIES & EQUIPMENT Exterior Lights - Corolla

Fig. 2: Identifying Fog Light Switch Positions & Connector Terminals Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 ACCESSORIES & EQUIPMENT Exterior Lights - Corolla

Fig. 3: Fog Light Switch Specifications Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. If continuity is not as specified, replace the switch. 2. Inspect fog light relay continuity

Fig. 4: Identifying Fog Light Relay Terminals & Wiring Diagram Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 ACCESSORIES & EQUIPMENT Exterior Lights - Corolla

Fig. 5: Fog Light Relay Specifications Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. If continuity is not as specified, replace the relay. ADJUSTMENT
Adjust Fog Light Aim

Fig. 6: Adjusting Fog Light Aiming Screw (Vertical Direction) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

TURN SIGNAL AND HAZARD WARNING SYSTEM LOCATION

2002 ACCESSORIES & EQUIPMENT Exterior Lights - Corolla

NOTE:

For manufactures precautions, see BODY, CAB CONTROL SYSTEMS . For circuit troubleshooting, see TURN SIGNAL AND HAZARD WARNING SYSTEM . For circuit wiring diagrams, see EXTERIOR LIGHTS .

LOCATION

Fig. 7: Locating Turn Signal And Hazard Warning System Components Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSPECTION

2002 ACCESSORIES & EQUIPMENT Exterior Lights - Corolla

1. Inspect turn signal switch continuity :

Fig. 8: Identifying Turn Signal Switch Positions & Locating Turn Signal Switch Terminals Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 ACCESSORIES & EQUIPMENT Exterior Lights - Corolla

Fig. 9: Turn Signal Switch Specifications Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. If continuity is not as specified, replace the switch. 2. Inspect hazard warning switch continuity :

Fig. 10: Identifying Hazard Warning Switch & Locating Hazard Warning Switch Terminals Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 ACCESSORIES & EQUIPMENT Exterior Lights - Corolla

Fig. 11: Hazard Warning Switch Specifications Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. If continuity is not as specified, replace the switch. 3. Inspect turn signal flasher operation : a. Connect the positive (+) lead from the battery to terminal 2 and the negative (-) lead to terminal 3.

Fig. 12: Testing Turn Signal Flasher Operation Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 ACCESSORIES & EQUIPMENT Exterior Lights - Corolla

NOTE:

The turn signal lights should flash 60 to 120 times per minute. If one of the front or rear turn signal lights has an open circuit, the number of flashes will be more than 140 per minute. If operation is not as specified, replace the flasher.

b. Connect the 2 turn signal light bulbs in parallel to each other to terminals 1 and 3, check that the bulbs flash.

BACK-UP LIGHT SYSTEM

NOTE: For manufacturers precautions, see BODY, CAB CONTROL SYSTEMS . For circuit troubleshooting, see BACK-UP LIGHT SYSTEM: . For circuit wiring diagrams, see EXTERIOR LIGHTS .

LOCATION

2002 ACCESSORIES & EQUIPMENT Exterior Lights - Corolla

Fig. 13: Locating Back-Up Light System Components Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSPECTION 1. M/T: Inspect back-up light switch continuity

2002 ACCESSORIES & EQUIPMENT Exterior Lights - Corolla

Fig. 14: Testing Back-Up Light Switch Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 15: Back-Up Light Switch Specifications Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. If continuity is not as specified, replace the switch.

2002 ACCESSORIES & EQUIPMENT Exterior Lights - Corolla

2. A/T: inspect park/neutral position switch continuity. For A-245E, PARK/NEUTRAL POSITION SWITCH . For A-131L, see PARK/NEUTRAL POSITION SWITCH .

STOP LIGHT SYSTEM

NOTE: For manufacturers precautions, see BODY, CAB CONTROL SYSTEMS . For circuit troubleshooting, see STOP LIGHT SYSTEM . For circuit wiring diagrams, see EXTERIOR LIGHTS .

LOCATION

2002 ACCESSORIES & EQUIPMENT Exterior Lights - Corolla

Fig. 16: Locating Stop Light System Components Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSPECTION
Inspect Stop Light Switch Continuity

W/O Cruise control system:

2002 ACCESSORIES & EQUIPMENT Exterior Lights - Corolla

Fig. 17: Identifying Stop Light Switch Positions & Locating Terminals (W/O Cruise Control) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 ACCESSORIES & EQUIPMENT Exterior Lights - Corolla

Fig. 18: Stop Light Switch Specifications (W/O Cruise Control) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. If continuity is not as specified, replace the switch. W/Cruise control system:

2002 ACCESSORIES & EQUIPMENT Exterior Lights - Corolla

Fig. 19: Identifying Stop Light Switch Positions & Locating Terminals (W/Cruise Control) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 ACCESSORIES & EQUIPMENT Exterior Lights - Corolla

Fig. 20: Stop Light Switch Specifications (W/Cruise Control) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. If continuity is not as specified, replace the switch.

2002 ACCESSORIES & EQUIPMENT Headlight And Taillight System - Corolla

2002 ACCESSORIES & EQUIPMENT Headlight And Taillight System - Corolla

HEADLIGHT AND TAILLIGHT SYSTEM

NOTE: For manufacturers precautions, see BODY, CAB CONTROL SYSTEMS . For circuit troubleshooting, see HEADLIGHT SYSTEM (EXCEPT TAIWAN) Or HEADLIGHT SYSTEM (TAIWAN) . For circuit wiring diagrams, see SYSTEM WIRING DIAGRAMS .

LOCATION

2002 ACCESSORIES & EQUIPMENT Headlight And Taillight System - Corolla

Fig. 1: Locating Headlight And Taillight System Components Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. COMPONENTS

2002 ACCESSORIES & EQUIPMENT Headlight And Taillight System - Corolla

Fig. 2: Identifying Combination Switch Components Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSPECTION 1. Inspect light control switch continuity :

2002 ACCESSORIES & EQUIPMENT Headlight And Taillight System - Corolla

Fig. 3: Identifying Light & Dimmer Control Switch Positions & Connector Terminals Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 ACCESSORIES & EQUIPMENT Headlight And Taillight System - Corolla

Fig. 4: Light Control Switch Specifications Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. If continuity is not as specified, replace the switch. 2. Inspect headlight dimmer switch continuity

Fig. 5: Headlight Dimmer Switch Specifications Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. If continuity is not as specified, replace the switch. 3. Inspect headlight control relay continuity :

2002 ACCESSORIES & EQUIPMENT Headlight And Taillight System - Corolla

Fig. 6: Identifying Headlight Control Relay Connector Terminals & Wiring Diagram Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 7: Headlight Control Relay Specifications Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. If continuity is not as specified, replace the relay. 4. Inspect taillight control relay continuity :

2002 ACCESSORIES & EQUIPMENT Headlight And Taillight System - Corolla

Fig. 8: Identifying Taillight Control Relay Terminals & Wiring Diagram Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 9: Headlight Taillight Control Relay Specifications Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. If continuity is not as specified, replace the relay. 5. Except TAIWAN, inspect headlight dimmer relay continuity :

2002 ACCESSORIES & EQUIPMENT Headlight And Taillight System - Corolla

Fig. 10: Identifying Headlight Dimmer Relay Terminals & Wiring Diagram Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 11: Headlight Dimmer Relay Specifications Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. If continuity is not as specified, replace the relay. 6. CANADA, inspect daytime running light relay (main) circuit : Disconnect the connector from the relay and inspect the connector on the wire harness side.

2002 ACCESSORIES & EQUIPMENT Headlight And Taillight System - Corolla

Fig. 12: Identifying Daytime Running Light Relay Terminals (CANADA) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 ACCESSORIES & EQUIPMENT Headlight And Taillight System - Corolla

Fig. 13: Daytime Running Light Relay Specifications (CANADA) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. If circuit is specified, try replacing the relay with a new one. If circuit is not as specified, inspect the circuits connected to other parts. 7. USA, Puerto Rico, inspect daytime running light relay (main) circuit :

2002 ACCESSORIES & EQUIPMENT Headlight And Taillight System - Corolla

Fig. 14: Identifying Daytime Running Light Relay Terminals (USA & Puerto Rico) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 ACCESSORIES & EQUIPMENT Headlight And Taillight System - Corolla

Fig. 15: Daytime Running Light Relay Specifications (USA & Puerto Rico) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Disconnect the connector from the relay and inspect the connector on the wire harness side. If circuit is specified, try replacing the relay with a new one. If circuit is not as specified, inspect the circuits connected to other parts. 8. Except TAIWAN, inspect daytime running light relay continuity :

2002 ACCESSORIES & EQUIPMENT Headlight And Taillight System - Corolla

Fig. 16: Identifying Daytime Running Light Relay Terminals & Wiring Diagram (Except TAIWAN) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 17: Daytime Running Light Relay Specifications (Except TAIWAN) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. If continuity is not as specified, replace the relay. 9. USA, Puerto Rico, inspect automatic light control : a. Turn the ignition switch ON. b. Turn the light control switch to OFF. c. Parking brake lever released. d. Gradually cover the top of the sensor.

2002 ACCESSORIES & EQUIPMENT Headlight And Taillight System - Corolla

Fig. 18: Locating Testing Automatic Light Control Operation Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 ACCESSORIES & EQUIPMENT Headlight And Taillight System - Corolla

Fig. 19: Testing Automatic Light Control Operation Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. e. Verify that the lights should turn ON the accessory lights and the headlights. 10. USA, Puerto Rico, inspect automatic light control : a. Turn the ignition switch ON. b. Turn the light control switch to OFF. c. Parking brake lever released. d. Cover the top of the light sensor. e. Head and tail lights turn ON. f. Gradually expose the light sensor. g. Tail light turn OFF and DRL light turn ON. 11. USA, Puerto Rico, inspect light-off condition : a. Turn the ignition switch ON. b. Turn the light control switch to OFF. c. Parking brake lever released. d. Lights auto ON: Gradually cover the top of the sensor. 12. USA, Puerto Rico, inspect lights-on condition : Turn the ignition switch OFF. 13. USA, Puerto Rico, inspect automatic light control sensor circuit :

2002 ACCESSORIES & EQUIPMENT Headlight And Taillight System - Corolla

a. Disconnect the connector from the sensor and inspect the connector on the wire harness side.

Fig. 20: Identifying Automatic Light Control Sensor Terminals (Wire Harness Side) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 21: Light Control Sensor Specifications (Wire Harness Side) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. If circuit is as specified, perform the inspection on the following page. If the circuit is not as specified, inspect the circuit connected to other parts.

2002 ACCESSORIES & EQUIPMENT Headlight And Taillight System - Corolla

NOTE:

Ignition switch ON. Light control switch AUTO. Vehicle's surroundings are bright.

Fig. 22: Identifying Automatic Light Control Sensor Terminals (Back Side) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 ACCESSORIES & EQUIPMENT Headlight And Taillight System - Corolla

Fig. 23: Light Control Sensor Specifications (Back Side) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Connect the wire harness side connector to the sensor and inspect wire harness side connector from the back side. If circuit is as specified, try replacing the sensor with a new one. If the circuit is not as specified, inspect the circuit connected to other parts. 14. Inspect light-on warning system (inspect integration relay operation) : a. Connect the positive (+) lead from the battery to terminal 3.

Fig. 24: Testing Light-On Warning System (1 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 ACCESSORIES & EQUIPMENT Headlight And Taillight System - Corolla

b. c. d. e.

Connect the negative (-) lead from the battery to terminals 7 and 11. Check that the bulb lights and the buzzer sounds for 4-8 seconds. Return to step and operate the buzzer sound again. Connect the positive (+) lead from the battery to terminal 9.

Fig. 25: Testing Light-On Warning System (2 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE: Check the buzzer sound within a period of 4 to 8 seconds. If operation is not as specified, replace the relay.

f. Check that the buzzer stops sounding. 15. Inspect light-on warning system (inspect integration relay circuit. See INSPECTION . ADJUSTMENT

2002 ACCESSORIES & EQUIPMENT Headlight And Taillight System - Corolla

Fig. 26: Adjusting Headlight Aim Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Adjust Headlight Aim Only

a. Put the vehicle in listed conditions. Make sure the body around the headlight is not deformed. Park the vehicle on a level spot. The driver gets into the driver's seat and puts the vehicle in a state ready for driving (with a full tank). Bounce the vehicle several times. Tire inflation pressure is the specified value. b. Prepare the thick white colored paper. c. Stand the paper perpendicularly and ensure the distance from it to the head lights is 3 m (9.84 ft). d. Ensure that the center line of vehicle and the paper are at a 90 degree angle as shown in the

2002 ACCESSORIES & EQUIPMENT Headlight And Taillight System - Corolla

illustration. e. Draw a horizontal line on the paper where the head lights (low beam center mark) of the vehicle are to be. f. Draw a vertical line on the paper where the center line of the vehicle is to be (V center line). g. Draw the vertical lines on the paper where the headlights (low beam center marks) of the vehicle are to be (V RH and LH lines). NOTE:

Disconnect the connector of the other light to avoid heat affection from the light because the outer lens of the head light assembly is made of synthetic resin. When connecting the connector again, take care not to make the aiming out of adjustment. When covering the headlight, finish it within 3 minutes.

h. Take an appropriate measure to avoid affecting the other light. i. Turn the headlight ON. NOTE: As shown in the illustration, adjust aiming of the LH and RH lights respectively.

2002 ACCESSORIES & EQUIPMENT Headlight And Taillight System - Corolla

Fig. 27: Headlight Aiming Diagram Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 ACCESSORIES & EQUIPMENT Headlight And Taillight System - Corolla

j. Check that the head lights light up the paper.

2002 ACCESSORIES & EQUIPMENT Interior/Illumination Lights - Corolla

2002 ACCESSORIES & EQUIPMENT Interior/Illumination Lights - Corolla

INTERIOR LIGHT SYSTEM

NOTE: For manufacturers precautions, see BODY, CAB CONTROL SYSTEMS . For troubleshooting circuit isolation table, see INTERIOR LIGHT SYSTEM . For circuit wiring diagrams, see INTERIOR LIGHTS .

LOCATION

2002 ACCESSORIES & EQUIPMENT Interior/Illumination Lights - Corolla

Fig. 1: Locating Interior Light System Components Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSPECTION 1. Inspect front personal light switch continuity :

2002 ACCESSORIES & EQUIPMENT Interior/Illumination Lights - Corolla

Fig. 2: Testing Front Personal Light Switch Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 ACCESSORIES & EQUIPMENT Interior/Illumination Lights - Corolla

Fig. 3: Front Personal Light Switch Specifications Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. If continuity is not as specified, replace the light assembly or bulb. 2. Inspect room light continuity : a. Disconnect the connector from the room light. b. Turn the room light switch ON, check that there is continuity between terminal 2 and body ground.

Fig. 4: Testing Room Light Continuity (1 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 ACCESSORIES & EQUIPMENT Interior/Illumination Lights - Corolla

c. Turn the room light switch DOOR, check that there is continuity between terminals 1 and 2.

Fig. 5: Testing Room Light Continuity (2 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. If continuity is not as specified, replace the light assembly or bulb. 3. Inspect map light continuity :

2002 ACCESSORIES & EQUIPMENT Interior/Illumination Lights - Corolla

Fig. 6: Identifying Map Light Positions & Terminals Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 ACCESSORIES & EQUIPMENT Interior/Illumination Lights - Corolla

Fig. 7: Map Light Specifications Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 4. Inspect front door courtesy switch continuity : a. Check that there is continuity between terminals and the switch body with the switch ON (switch pin released: opened door).

2002 ACCESSORIES & EQUIPMENT Interior/Illumination Lights - Corolla

Fig. 8: Testing Front Door Courtesy Switch Continuity Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Check that there is no continuity between terminals and the switch body with the switch OFF (switch pin pushed in: closed door). If operation is not as specified, replace the switch. 5. Inspect rear door courtesy switch continuity : a. Check that there is continuity between terminals and the switch body with the switch ON (switch pin released: opened door).

2002 ACCESSORIES & EQUIPMENT Interior/Illumination Lights - Corolla

Fig. 9: Testing Rear Door Courtesy Switch Continuity Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Check that there is no continuity between terminals and the switch body with the switch OFF (switch pin pushed in: closed door). If operation is not as specified, replace the switch. 6. Inspect luggage compartment door courtesy switch continuity : a. Check that there is continuity between terminals and the switch body with the switch ON (switch pin released: opened door).

2002 ACCESSORIES & EQUIPMENT Interior/Illumination Lights - Corolla

Fig. 10: Testing Luggage Compartment Door Courtesy Switch Continuity Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Check that there is no continuity between terminals and the switch body with the switch OFF (switch pin pushed in: closed door). If operation is not as specified, replace the switch. 7. Inspect luggage compartment light continuity : Using the ohmmeter, check that there is continuity between terminals.

2002 ACCESSORIES & EQUIPMENT Interior/Illumination Lights - Corolla

Fig. 11: Testing Luggage Compartment Light Continuity Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. If continuity is not as specified, replace the light assembly or bulb.

CABIN AIR FILTERS Air Refiner Filter & Air Conditioning Filter - Corolla & Matrix

CABIN AIR FILTERS Air Refiner Filter & Air Conditioning Filter - Corolla & Matrix

REMOVAL & INSTALLATION

NOTE: Manufacturer's terminology for this filter is air refiner filter or air conditioning filter.

CABIN AIR FILTER

Removal & Installation (2002-2006)

1. Open the glove box. 2. Remove the screw with a phillips-head screwdriver and slide off the damper. See Fig. 1 .

Fig. 1: Locating Glove Box Screw & Damper Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 3. Push each side of the glove box to disconnect the claws.Allow glove box door to hang down.

CABIN AIR FILTERS Air Refiner Filter & Air Conditioning Filter - Corolla & Matrix

4. Remove the filter cover. See Fig. 2 .

Fig. 2: Removing Filter Cover Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 5. Remove the filter from the filter outlet. See Fig. 3 .

CABIN AIR FILTERS Air Refiner Filter & Air Conditioning Filter - Corolla & Matrix

Fig. 3: Removing Filter Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 6. Inspect the filter on the surface. If it is dirty, it should be replaced. 7. To install, reverse removal procedure.When installing the filter, ensure arrow mark ("UP" mark) on edge of filter points up.Using the A/C without the filter installed may cause deteriorated dustproof performance and may affect A/C performance.

2002 MANUAL A/C-HEATER SYSTEMS Air Conditioning - Corolla

2002 MANUAL A/C-HEATER SYSTEMS Air Conditioning - Corolla

AIR CONDITIONING SYSTEM

PRECAUTION 1. Do not handle refrigerant in an enclosed area or near an open flame . 2. Always wear eye protection . 3. Be careful not to get liquid refrigerant in your eyes or on your skin . If liquid refrigerant gets in your eyes or on your skin. WARNING: Do not rub your eyes or skin.

a. Wash the area with lots of cool water. b. Apply clean petroleum jelly to the skin. c. Go immediately to a physician or hospital for professional treatment. 4. Never heat container or expose it to naked flame . 5. Be careful not to drop container and not to apply physical shocks to it . 6. Do not operate compressor without enough refrigerant in refrigerant system .

2002 MANUAL A/C-HEATER SYSTEMS Air Conditioning - Corolla

Fig. 1: Identifying Charging Side Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. If there is not enough refrigerant in the refrigerant system oil lubrication will be insufficient and compressor burnout may occur, so take care to avoid this, necessary care should be taken. 7. Do not open high pressure manifold valve while compressor is operating . If the high pressure valves opened, refrigerant flows in the reverse direction and could cause the charging cylinder to rupture, so open and close the only low pressure valve. 8. Be careful not to overcharge system with refrigerant . If refrigerant is overcharged, it causes problems such as insufficient cooling, poor fuel economy, engine overheating etc. 9. SUPPLEMENTAL RESTRAINT SYSTEM (SRS)

2002 MANUAL A/C-HEATER SYSTEMS Air Conditioning - Corolla

The COROLLA is equipped with as SRS (Supplemental Restraint System) such as the driver and passenger air bag. Failure to carry out service operations the correct sequence could cause the SRS to unexpectedly deployed during servicing, possibly leading to a serious accident. Further, if a mistake is made in servicing the SRS, it is possible the SRS may fail to operate when required. Before servicing (including removal or installation of parts, inspection or replacement), be sure to read the following item carefully, then follow the correct procedure described in article . ON-VEHICLE INSPECTION 1. Inspect refrigerant volume . Observe the sight glass on the liquid tube.

Fig. 2: Locating Refrigerant Site Glass Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 MANUAL A/C-HEATER SYSTEMS Air Conditioning - Corolla

Fig. 3: Understanding Conditions Indicated By Site Glass Readings Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Test conditions:

Running engine at 1,500 RPM. Blower speed control switch at "HI" position. A/C switch ON. Temperature control dial at "COOL" position. Fully open the doors. It should be noted that the gauge indications may vary slightly due to ambient temperature conditions.

NOTE:

2. Inspect refrigerant pressure with manifold gauge set : This is a method in which the trouble is located by using a manifold gauge set. Read the manifold gauge pressure when these conditions are established. Test conditions: Temperature at the air inlet with the switch set at RECIRC is 30-50C (86-95F). Engine running at 2,000 RPM. Blower speed control switch at "HI" position. Temperature control dial on "COOL" position. 1. Normally functioning refrigeration system:

2002 MANUAL A/C-HEATER SYSTEMS Air Conditioning - Corolla

Fig. 4: Manifold Gauge Reading Normal Conditions Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Gauge reading: Low pressure side: 0.15-0.25 MPa (1.5-2.5 kg/cm 2 ) . High pressure side: 1.37-1.55 MPa (14-15 kg/cm 2 ) . 2. Moisture present in refrigeration system:

2002 MANUAL A/C-HEATER SYSTEMS Air Conditioning - Corolla

Fig. 5: Manifold Gauge Reading Moisture Present In System Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 6: Diagnosis Chart Symptoms Of Moisture In System Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 3. Insufficient cooling:

Fig. 7: Manifold Gauge Reading Insufficient Cooling Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 MANUAL A/C-HEATER SYSTEMS Air Conditioning - Corolla

Fig. 8: Diagnosis Chart Insufficient Cooling Symptoms Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 4. Poor circulation of refrigerant:

Fig. 9: Manifold Gauge Reading Poor Refrigerant Circulation Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 10: Diagnosis Chart Poor Circulation Of Refrigerant Symptoms Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 5. Refrigerant does not circulate:

2002 MANUAL A/C-HEATER SYSTEMS Air Conditioning - Corolla

Fig. 11: Manifold Gauge Reading No Refrigerant Circulation Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 12: Diagnosis Chart No Refrigerant Circulation Symptoms Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 6. Refrigerant overcharged or insufficient cooling of condenser:

Fig. 13: Manifold Gauge Reading Refrigerant Overcharged Or Condenser Insufficiently

2002 MANUAL A/C-HEATER SYSTEMS Air Conditioning - Corolla

Cooled Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 14: Diagnosis Chart Refrigerant Overcharged Or Condenser Insufficiently Cooled Symptoms Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 7. Air present in refrigeration system:

Fig. 15: Manifold Gauge Reading Air Present In Refrigeration System Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 16: Diagnosis Chart Air Present In Refrigeration System Symptoms Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 8. Expansion valve improperly:

2002 MANUAL A/C-HEATER SYSTEMS Air Conditioning - Corolla

Fig. 17: Manifold Gauge Reading Improper Operation Of Expansion Valve Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 18: Diagnosis Chart Improper Operation Of Expansion Valve Symptoms Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 9. Defective compression compressor:

Fig. 19: Manifold Gauge Reading Defective Compressor Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 MANUAL A/C-HEATER SYSTEMS Air Conditioning - Corolla

Fig. 20: Diagnosis Chart Defective Compressor Symptoms Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 3. Inspect idle-up speed : a. Warm up engine b. Inspect idle-up speed when the these conditions are established. Test conditions:

Blower speed control switch at "HI" position. Temperature control dial at "COOL" position. A/C switch ON. Put gear shift in neutral.

Fig. 21: Idle Speed Specifications Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. If idle speed is not as specified, check the idle control system. 4. Inspect for leakage or refrigerant : a. Perform in these conditions. Stop engine Secure good ventilation (If the gas leak detector may not react to volatile gases which are not refrigerant, such as evaporated gasoline and exhaust gas). Repeat the test 2 or 3 times. Make sure that there is some refrigerant remaining in the refrigeration system. When compressor is OFF: approx. 392-588 kPa (4-6 kgf/cm2 , 57-85 psi).

2002 MANUAL A/C-HEATER SYSTEMS Air Conditioning - Corolla

NOTE:

After the blower motor has stopped, leave the cooling for more than 15 minutes. Expose the gas leak detector sensor under the drain hose. When bring the gas leak detector close to the drain hose, make sure that the gas leak detector does not react to the volatile gases.

b. Bring the gas leak detector close to the drain hose before performing the test. If such reaction is unavoidable, the vehicle must be lifted up. c. If gas leak is not detected on the drain hose, remove the blower resistor from the cooling unit. Then insert the gas leak detector sensor into the unit and perform the test. d. Disconnect the connector and leave the pressure switch for approx. 20 minutes. Then bring the gas leak detector close to the pressure switch and perform the test. e. Bring the gas leak detector close to the refrigerant lines. EVACUATING 1. Connect quick disconnect adapter to charging hoses .

Fig. 22: Installing Quick Disconnect Adapter Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 MANUAL A/C-HEATER SYSTEMS Air Conditioning - Corolla

2. Remove caps from service valves on refrigerant lines . 3. Set on manifold gauge set : a. Close both hand valves of manifold gauge set. b. Connect the quick disconnect adapters to the service valves. 4. Evacuate air from refrigeration system : a. Connect the vacuum pump adapter to the vacuum pump.

Fig. 23: Connecting Quick Disconnect Adapter To Vacuum Pump Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Connect the center hose of the manifold gauge set to the vacuum pump adapter.

2002 MANUAL A/C-HEATER SYSTEMS Air Conditioning - Corolla

2002 MANUAL A/C-HEATER SYSTEMS Air Conditioning - Corolla

Fig. 24: Connecting Manifold Gauge Set To System & Vacuum Pump Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Open both the high and low hand valves and run the vacuum pump. NOTE: If the reading is 750 mm/Hg (30 in.Hg) or more, close both hand valves of manifold gauge set and stop the vacuum pump. Check the system for leaks and repair if necessary. d. After 10 minutes or more, check that the low pressure gauge indicates 750 mm/Hg (30 in.Hg) or more. e. Close both the high and low hand valves and stop the vacuum pump. f. Leave the system in this condition for 5 minutes or more and check that there is no gauge indicator. CHARGING WARNING: When handling the charging cylinder, always follow the directions given in the instruction manual. 1. Install charging cylinder a. Charge the proper amount of refrigerant into the charging cylinder. WARNING: Do not open both high and low hand valves of manifold gauge set. b. Connect the center hose to the charging cylinder. c. Open the valve of charging cylinder.

2002 MANUAL A/C-HEATER SYSTEMS Air Conditioning - Corolla

Fig. 25: Opening Charging Cylinder Valve Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. d. Press the valve core on the side of manifold gauge and expel the air inside of the center hose.

2002 MANUAL A/C-HEATER SYSTEMS Air Conditioning - Corolla

CAUTION: Use the refrigerant recovery/recycling machine to recover the refrigerant whenever replacing parts. 2. Inspect refrigeration system for leaks : a. Open the high pressure hand valve and charge refrigerant. b. When the low pressure gauge indicates 98 kPa (1 kgf/cm2 , 14 psi) close the high pressure hand valve. c. Using a gas leak detector, check the system for leakage.

2002 MANUAL A/C-HEATER SYSTEMS Air Conditioning - Corolla

Fig. 26: Identifying Gas Leak Detector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. If leak is found, repair the faulty component or connection. WARNING: When handling the charging cylinder, always follow the directions given in the instruction manual.

2002 MANUAL A/C-HEATER SYSTEMS Air Conditioning - Corolla

Fig. 27: Connecting Manifold Gauge Set To System & Charging Cylinder Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 3. Install charging cylinder . a. Charge the proper amount of refrigerant into the charging cylinder.

2002 MANUAL A/C-HEATER SYSTEMS Air Conditioning - Corolla

WARNING: Do not open both high and low hand valves of manifold gauge set. b. Connect the center hose to the charging cylinder. c. Open the valve of charging cylinder. d. Press the valve core on the side of manifold gauge and expel the air inside of the center hose. A fully charged system is indicated by the sight glass being free of any bubbles. 4. Set off manifold gauge set : a. Close both hand valves of manifold gauge set. b. Disconnect the quick disconnect adapters from the service valves. 5. Install caps to service valves on refrigerant lines . LOCATION

2002 MANUAL A/C-HEATER SYSTEMS Air Conditioning - Corolla

Fig. 28: Locating A/C System Components Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

TROUBLESHOOTING
PROBLEM SYMPTOMS TABLE Use the table below to help you find the cause of the problem. The numbers indicate the priority of the likely cause of the problem. Check each part in order. If necessary, replace these parts.

2002 MANUAL A/C-HEATER SYSTEMS Air Conditioning - Corolla

Fig. 29: Problem Symptoms Table Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

DRIVE BELT
ON-VEHICLE INSPECTION Check that the drive belt fits properly in the ribbed grooves.

2002 MANUAL A/C-HEATER SYSTEMS Air Conditioning - Corolla

Fig. 30: Identifying Correct Drive Belt Installation Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL Loosen the drive belt tension by turning the drive belt tensioner clockwise, and remove the drive belt.

Fig. 31: Removing Drive Belt Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 MANUAL A/C-HEATER SYSTEMS Air Conditioning - Corolla

INSTALLATION 1. Install drive belt : Turning the drive belt tensioner clockwise, and install the drive belt.

Fig. 32: Installing Drive Belt Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 2. Check drive belt installing condition . See ON-VEHICLE INSPECTION .

MANIFOLD GAUGE SET

SET ON WARNING: Do not connect the wrong hoses.

2002 MANUAL A/C-HEATER SYSTEMS Air Conditioning - Corolla

Fig. 33: Connecting Manifold Gauge Set To Vehicle Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 MANUAL A/C-HEATER SYSTEMS Air Conditioning - Corolla

1. Connect charging hoses to manifold gauge set : Tighten the nuts by hand. NOTE: Push the quick disconnect adapter onto the service valve, then slide the sleeve of the quick disconnect adapter downward to lock it.

Fig. 34: Connecting Quick Disconnect Adapters Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 2. Connect quick disconnect adapters to charging hoses . Tighten the nuts by hand. 3. Close both hand valves of manifold gauge set . 4. Remove caps from service valves on refrigerant lines . 5. Connect quick disconnect adapters to service valves . SET OFF 1. Close both hand valves of manifold gauge set .

2002 MANUAL A/C-HEATER SYSTEMS Air Conditioning - Corolla

NOTE:

Slide the sleeve of the quick disconnect adapter upward to unlock the adapter and remove it from the service valve.

Fig. 35: Disconnecting Quick Disconnect Adapters Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 2. Disconnect quick disconnect adapters from service valves on refrigerant line . 3. Install caps to service valves on refrigerant lines .

REFRIGERANT LINE
ON-VEHICLE INSPECTION 1. Inspect hose and tube connections for looseness . 2. Inspect hoses and tubes for leakage . Using a gas leak detector, check for leakage of refrigerant.

2002 MANUAL A/C-HEATER SYSTEMS Air Conditioning - Corolla

COMPONENTS

Fig. 36: Identifying A/C Hoses & Connections & Mounting Bolt Locations Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REPLACEMENT 1. Discharge refrigerant from refrigeration system . CAUTION: Cap the open fittings immediately to keep moisture or dirt out of the system. 2. Replace faulty tube or hose .

2002 MANUAL A/C-HEATER SYSTEMS Air Conditioning - Corolla

CAUTION: Connections should not be torqued tighter than the specified torqued. 3. Tighten joint of bolt or nut at specified torque . See TORQUE SPECIFICATIONS . 4. Evacuate air in refrigeration system and charge with refrigerant : Specified amount: 650 +/- 50 g (22.93 +/- 1.76 oz.) 5. Using a gas leak detector, check for leakage of refrigerant. . 6. Inspect air conditioning operation .

COOLING UNIT
ON-VEHICLE INSPECTION 1. 2. 3. 4. Remove FRONT DOOR SCUFF PLATE RH . Remove COWL SIDE TRIM RH . Remove LOWER PANEL . Remove blower resistor : a. Disconnect the connector.

Fig. 37: Locating Blower Resistor Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 MANUAL A/C-HEATER SYSTEMS Air Conditioning - Corolla

b. Remove the 2 screws and the blower resistor. 5. Inspect evaporator and fittings for leakage : Using a gas leak detector, check for leakage. If there leakage, check the tightening torque at the joints or check the evaporator. 6. Check quantity of gas during refrigeration cycle . 7. Set on manifold gauge set . See MANIFOLD GAUGE SET . 8. Run engine : a. Run the engine at 1,500 RPM for at least 5 minutes. b. Then check that the high pressure reading is 1.37-1.57 MPa (14-16 kgf.cm2 , 199-228 psi). NOTE: When the low pressure drops to 0 kPa (0 kgf.cm2 , 0 psi), feel the receiver's IN and OUT sides for no temperature difference.

9. Check expansion valve : If the expansion valve is faulty, low pressure reading will drop to 0 kPa (0 kgf.cm2 , 0 psi). 10. Inspect thermistor resistance : a. Disconnect the connector.

2002 MANUAL A/C-HEATER SYSTEMS Air Conditioning - Corolla

Fig. 38: Identifying Thermistor Terminals & Testing Thermistor Resistance Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Measure resistance between terminals 3 and 4. Standard resistance: 1,500 ohm at 25C (77 F) . If resistance is not as specified, replace the thermistor. COMPONENTS

2002 MANUAL A/C-HEATER SYSTEMS Air Conditioning - Corolla

Fig. 39: Locating Passenger Compartment A/C Components Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL 1. Discharge refrigerant from refrigeration system . 2. Disconnect cruise control actuator connector . 3. Remove 3 cruise control actuator set bolts .

Fig. 40: Locating Cruise Control Actuator Mounting Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 4. Disconnect liquid and suction tubes . a. Remove the suction hose piping clamp set nut.

2002 MANUAL A/C-HEATER SYSTEMS Air Conditioning - Corolla

Fig. 41: Locating Suction Hose Piping Clamp Set Nut Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Using SST, remove the piping clamps. SST 09870-00015 (Suction tube) 09870-00025 (Liquid tube).

2002 MANUAL A/C-HEATER SYSTEMS Air Conditioning - Corolla

Fig. 42: Locating Piping Clamps Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE: Confirm the direction of the piping clamp claw and SST using the illustration showing on the caution label.

2002 MANUAL A/C-HEATER SYSTEMS Air Conditioning - Corolla

Fig. 43: Using Piping Clamp SST (1 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 1. Insert SST to piping clamp. CAUTION: Be careful not to deform the tubes, when pushing SST.

2002 MANUAL A/C-HEATER SYSTEMS Air Conditioning - Corolla

Fig. 44: Using Piping Clamp SST (2 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 2. Push down SST and release the clamp lock. 3. Pull SST slightly and push the release lever, then remove piping clamp with SST. 4. Remove the piping clamp from SST. CAUTION: Cap the open fittings immediately to keep moisture or dirt out of the system. c. Disconnect the both tubes. 5. Remove tube grommet and drain hose grommet . 6. Remove LOWER FINISH PANEL . 7. Remove A/C amplifier : a. Disconnect the connector. b. Remove the 2 nuts and amplifier.

2002 MANUAL A/C-HEATER SYSTEMS Air Conditioning - Corolla

Fig. 45: Locating A/C Amplifier Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 8. Remove cooling unit : a. Disconnect the connectors. b. Remove the 3 screws, nut and cooling unit.

2002 MANUAL A/C-HEATER SYSTEMS Air Conditioning - Corolla

Fig. 46: Locating Cooling Unit Mounting Bolts & Nut Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. DISASSEMBLY 1. Remove blower resistor : Remove the 2 screws and blower resistor. 2. Separate cooling unit cases : a. Disconnect the thermistor connector.

2002 MANUAL A/C-HEATER SYSTEMS Air Conditioning - Corolla

Fig. 47: Locating Cooling Unit Case Clamps & Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Using a knife, cut off each packing. c. Remove the 4 screws and 3 clips, then separate the cooling unit cases. 3. Remove evaporator from cooling unit case . 4. Pull out the thermistor from the evaporator .

2002 MANUAL A/C-HEATER SYSTEMS Air Conditioning - Corolla

Fig. 48: Locating Thermistor Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 5. Remove expansion valve : Using a hexagon wrench (5.0 mm, 0.20 in.), remove the 2 bolts and separate the expansion valve, evaporator, liquid and suction tube.

2002 MANUAL A/C-HEATER SYSTEMS Air Conditioning - Corolla

Fig. 49: Locating Expansion Valve Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSPECTION NOTE: Never use to clean the evaporator.

1. Check evaporator fins for blockage : If the fins clogged, clean them with compressed air.

2002 MANUAL A/C-HEATER SYSTEMS Air Conditioning - Corolla

2. Check fittings for cracks or scratches : If necessary, repair or replace. 3. Inspect thermistor resistance : a. Place the sensor in cold water, and while changing the temperature of the water, measure resistance at the connector and at the same time, measure temperature of the water with a thermometer.

Fig. 50: Testing Thermistor Operation Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Compare the 2 readings on the chart.

2002 MANUAL A/C-HEATER SYSTEMS Air Conditioning - Corolla

Fig. 51: Thermistor Resistance Chart Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. If resistance value is not as specified, replace the sensor. REASSEMBLY 1. Install expansion valve : a. Lubricate 4 new O-rings, with compressor oil and install them to the expansion valve. b. Using a hexagon wrench (5.0 mm, 0.20 in.), install the expansion valve with the 2 bolts. Torque: 5.4 N.m (55 kgf.cm 48 in..lbf) .

2002 MANUAL A/C-HEATER SYSTEMS Air Conditioning - Corolla

Fig. 52: Locating expansion valve Mounting bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 2. Install the thermistor to the evaporator :

2002 MANUAL A/C-HEATER SYSTEMS Air Conditioning - Corolla

Fig. 53: Locating Thermistor Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE: If evaporator is replaced, add compressor oil to the evaporator. Add 40 cc (1.4 fl.oz.) . Compressor oil: ND-OIL 8 or equivalent.

2002 MANUAL A/C-HEATER SYSTEMS Air Conditioning - Corolla

Fig. 54: Locating Cooling Unit Case Clamps & Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 3. Install evaporator to cooling unit case : 4. Install cooling unit cases : a. Install the cooling unit cases with the 4 screws and 3 clips. b. Install the new packing. c. Connect the thermistor connector. 5. Install the blower resistor with the 2 screws . INSTALLATION 1. Install cooling unit : a. Install the cooling unit with the 3 screws and nut. b. Connect the connectors.

2002 MANUAL A/C-HEATER SYSTEMS Air Conditioning - Corolla

Fig. 55: Locating Cooling Unit Mounting Bolts & Nut Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 2. Install A/C amplifier : a. Install the amplifier with the 2 nuts.

2002 MANUAL A/C-HEATER SYSTEMS Air Conditioning - Corolla

Fig. 56: Locating A/C Amplifier Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Connect the connector. 3. Install LOWER FINISH PANEL . 4. Install tube grommet and drain hose grommet . 5. Connect liquid and suction tubes : a. Lubricate 4 new O-rings with compressor oil and install them to the tubes. b. Connect the connector.

2002 MANUAL A/C-HEATER SYSTEMS Air Conditioning - Corolla

Fig. 57: Locating Piping Clamps Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. After connection, check the fitting for claw of the piping clamp.

Fig. 58: Inspecting Piping Clamp Claw Fitting

2002 MANUAL A/C-HEATER SYSTEMS Air Conditioning - Corolla

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. d. Install the suction hose piping clamp set nut.

Fig. 59: Locating Suction Hose Piping Clamp Set Nut Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 6. Install 3 cruise control actuator set bolts :

2002 MANUAL A/C-HEATER SYSTEMS Air Conditioning - Corolla

Fig. 60: Locating Cruise Control Actuator Mounting Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 7. Connect cruise control actuator connector . 8. Charge refrigerant to refrigeration system : a. Evacuate air from refrigeration system. b. Charge system with refrigerant.Specified amount: 650 +/- 50 g (22.93 +/- 1.76 oz.) . 9. Inspect for leakage of refrigerant : Using a gas leak detector, check for leakage of refrigerant. If there is leakage, check the tightening torque at the joints or check fitting for claw of piping clamp.

HEATER UNIT
COMPONENTS

2002 MANUAL A/C-HEATER SYSTEMS Air Conditioning - Corolla

Fig. 61: Locating Heater Unit Components Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL 1. Remove cooling unit . See REMOVAL . NOTE: It is not necessary to drain out all the coolant.

2. Drain engine coolant from radiator . 3. Disconnect water hoses from heater radiator pipes :

2002 MANUAL A/C-HEATER SYSTEMS Air Conditioning - Corolla

a. Using pliers, grip the claw of the hose clip and slide the clip along the hose.

Fig. 62: Locating Heater Hose To Heater Radiator Pipe Connections Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disconnect the water hoses from heater radiator pipes. 4. Remove INSTRUMENT PANEL AND REINFORCEMENT . 5. Remove rear heater ducts : a. Slide the floor carpet backward. b. Remove the rear heater ducts.

2002 MANUAL A/C-HEATER SYSTEMS Air Conditioning - Corolla

Fig. 63: Locating Rear Heater Ducts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 6. Remove heater unit : a. Disconnect the wire harness clamp from the heater unit. b. Remove the 3 nut and heater unit.

2002 MANUAL A/C-HEATER SYSTEMS Air Conditioning - Corolla

Fig. 64: Locating Heater Unit & Mounting Nuts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. DISASSEMBLY 1. Remove air duct : a. Remove the screw. NOTE: Tape the screwdriver, tip before use.

b. Using a screwdriver, release the 5 claws and remove the duct. NOTE: Tape the screwdriver, tip before use.

2. Using a screwdriver, release the 2 claws and remove the cover . 3. Remove the screw, clamp and pull out the heater radiator :

2002 MANUAL A/C-HEATER SYSTEMS Air Conditioning - Corolla

Fig. 65: Locating Heater Radiator Mounting Screw Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSPECTION
Inspect Fins For Blockage

If the fins are clogged, clean them with compressed air. REASSEMBLY 1. Install the heater radiator with the screw and clamp .

2002 MANUAL A/C-HEATER SYSTEMS Air Conditioning - Corolla

Fig. 66: Locating Heater Radiator Mounting Screw Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 2. Install the cover . 3. Install the air duct with the screw. INSTALLATION 1. Install heater unit : a. Instal the heater unit with the 3 nuts.

2002 MANUAL A/C-HEATER SYSTEMS Air Conditioning - Corolla

Fig. 67: Locating Heater Unit & Mounting Nuts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Connect the wire harness clamp to the heater unit. 2. Install rear heater ducts .

2002 MANUAL A/C-HEATER SYSTEMS Air Conditioning - Corolla

Fig. 68: Identifying Rear Heater Ducts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 3. Connect water hoses to heater radiator : a. Push the water hose onto the heater radiator pipe as far as the second ridge on the pipe.

2002 MANUAL A/C-HEATER SYSTEMS Air Conditioning - Corolla

Fig. 69: Locating Heater Hose To Heater Radiator Pipe Connections Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Install the hose clip in a position, as shown in the illustration.

2002 MANUAL A/C-HEATER SYSTEMS Air Conditioning - Corolla

Fig. 70: Installing Hose Clip Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 4. Fill with engine coolant . 5. Install cooling unit . See INSTALLATION .

BLOWER UNIT
COMPONENTS

2002 MANUAL A/C-HEATER SYSTEMS Air Conditioning - Corolla

Fig. 71: Identifying Blower Unit Components Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL 1. Remove cooling unit . See REMOVAL . 2. Remove blower unit : a. Disconnect the connectors. b. Remove the nut and blower unit.

2002 MANUAL A/C-HEATER SYSTEMS Air Conditioning - Corolla

Fig. 72: Locating Blower Unit Mounting Nut & Connector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. DISASSEMBLY 1. Remove blower motor : Using a torx wrench, remove the 3 screws and blower motor. 2. Inspect blower motor . See INSPECTION . REASSEMBLY

2002 MANUAL A/C-HEATER SYSTEMS Air Conditioning - Corolla

Install Blower Motor

Using a torx wrench, install the blower motor with the 3 screws. INSTALLATION 1. Install blower unit . a. Install the blower unit with the nut.

Fig. 73: Locating Blower Unit Mounting Nut & Connector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 MANUAL A/C-HEATER SYSTEMS Air Conditioning - Corolla

b. Connect the connectors. 2. Install cooling unit . See INSTALLATION .

COMPRESSOR AND MAGNETIC CLUTCH

ON-VEHICLE INSPECTION 1. Inspect compressor for metallic sound : Check there is abnormal metallic sound from the compressor when the A/C switch is ON. If abnormal metallic sound is heard, replace the compressor assembly. 2. Inspect refrigerant pressure . 3. Inspect visually for leakage of refrigerant . Using a gas leak detector, check for leakage of refrigerant. If there is any leakage, replace the compressor assembly. 4. Inspect compressor lock sensor resistance : a. Disconnect the connector.

Fig. 74: Identifying Compressor Terminal 2 Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 MANUAL A/C-HEATER SYSTEMS Air Conditioning - Corolla

b. Measure the resistance between terminals 1 and 2. Standard resistance: 65-125 ohm at 20C (68F) . If resistance is not as specified, replace the sensor. 5. Check for leakage of from clutch bearing . 6. Check for signs of oil pressure plate or rotor . 7. Inspect magnetic clutch bearing for noise : a. Start engine. b. Check for abnormal noise from the compressor when the A/C switch is OFF. If abnormal noise is being emitted, replace the magnetic clutch. 8. Inspect magnetic clutch operation : a. Disconnect the connector. b. Connect the positive (+) lead from the battery to terminal 4 and the negative (-) lead to the body ground.

Fig. 75: Identifying Compressor Terminal 4 Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Check that the magnetic clutch energized. If operation is not as specified, replace the magnetic clutch.

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COMPONENTS

Fig. 76: Identifying Compressor Components Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL 1. 2. 3. 4. Run engine at idle speed with A/C on for approx. 10 minutes . Stop engine . Disconnect negative (-) terminal cable from battery . Discharge refrigerant from refrigeration system .

2002 MANUAL A/C-HEATER SYSTEMS Air Conditioning - Corolla

5. Remove engine under cover . 6. Remove drive belt . CAUTION: Cap the open fittings immediately to keep moisture or dirt out of the system.

Fig. 77: Locating Discharge & Suction Hose To Compressor Mounting Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 7. Disconnect discharge and suction hoses from compressor . Remove the 2 bolts and disconnect the both hoses. 8. Remove compressor : a. Disconnect the connector. b. Remove the 3 bolts and compressor.

2002 MANUAL A/C-HEATER SYSTEMS Air Conditioning - Corolla

Fig. 78: Locating Compressor Mounting Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. DISASSEMBLY 1. Remove pressure plate : a. Using SST and a socket wrench, remove the shaft bolt. SST 07112-76060.

2002 MANUAL A/C-HEATER SYSTEMS Air Conditioning - Corolla

Fig. 79: Removing Shaft Bolt Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Install SST on the pressure plate. SST 07112-66040.

2002 MANUAL A/C-HEATER SYSTEMS Air Conditioning - Corolla

Fig. 80: Installing SST On Pressure Plate Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Using SST and a socket wrench, remove the pressure plate. SST 07112-66040, 07112-76060.

2002 MANUAL A/C-HEATER SYSTEMS Air Conditioning - Corolla

Fig. 81: Removing Pressure Plate Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. d. Remove the shims from the pressure plate.

2002 MANUAL A/C-HEATER SYSTEMS Air Conditioning - Corolla

Fig. 82: Removing & Installing Pressure Plate Shims Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 2. Remove rotor : a. Using SST, remove the snap ring. SST 95994-10020 (DENSO Part No.).

2002 MANUAL A/C-HEATER SYSTEMS Air Conditioning - Corolla

Fig. 83: Removing & Installing Rotor Snap Ring Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Using a plastic hammer, tap the rotor off the shaft.

2002 MANUAL A/C-HEATER SYSTEMS Air Conditioning - Corolla

Fig. 84: Removing Rotor From Shaft Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE: Be careful not to damage the pulley when tapping on the rotor.

3. Remove stator : a. Disconnect the stator lead wire from the compressor housing.

2002 MANUAL A/C-HEATER SYSTEMS Air Conditioning - Corolla

Fig. 85: Connecting & Disconnecting Stator Lead Wire Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Using SST, remove the snap ring. SST 95994-10020 (DENSO Part No.).

2002 MANUAL A/C-HEATER SYSTEMS Air Conditioning - Corolla

2002 MANUAL A/C-HEATER SYSTEMS Air Conditioning - Corolla

Fig. 86: Removing & Installing Stator Snap Ring Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Remove the stator.

Fig. 87: Removing & Installing Stator Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REASSEMBLY

2002 MANUAL A/C-HEATER SYSTEMS Air Conditioning - Corolla

1. Install stator : a. Install the stator.

Fig. 88: Removing & Installing Stator Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE: The snap ring should be installed so that its beveled side faces up.

2002 MANUAL A/C-HEATER SYSTEMS Air Conditioning - Corolla

Fig. 89: Identifying Proper Snap Ring Installation Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 MANUAL A/C-HEATER SYSTEMS Air Conditioning - Corolla

Fig. 90: Removing & Installing Stator Snap Ring Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Using SST, install the snap ring. SST 95994-10020 (DENSO Part No.). c. Connect the stator lead wire to the compressor housing.

2002 MANUAL A/C-HEATER SYSTEMS Air Conditioning - Corolla

Fig. 91: Connecting & Disconnecting Stator Lead Wire Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 2. Install rotor : a. Install the rotor. NOTE: The snap ring should be installed so that beveled side faces up.

2002 MANUAL A/C-HEATER SYSTEMS Air Conditioning - Corolla

Fig. 92: Identifying Proper Snap Ring Installation Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 MANUAL A/C-HEATER SYSTEMS Air Conditioning - Corolla

Fig. 93: Removing & Installing Rotor Snap Ring Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Using SST, install the snap ring. SST 95994-10020 (DENSO Part No.). 3. Install pressure plate : a. Install the shims to the pressure plate and install the pressure plate on the rotor.

2002 MANUAL A/C-HEATER SYSTEMS Air Conditioning - Corolla

Fig. 94: Removing & Installing Pressure Plate Shims Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Using SST and a torque wrench, install the shaft bolt. SST 07112-66040, 07112-76060. Torque: 13.2 N.m (135 kgf.cm, 9 ft.lbf) .

2002 MANUAL A/C-HEATER SYSTEMS Air Conditioning - Corolla

Fig. 95: Installing Shaft Bolt Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 4. Inspect magnetic clutch clearance : a. Set the dial indicator to the pressure plate of the magnetic clutch.

2002 MANUAL A/C-HEATER SYSTEMS Air Conditioning - Corolla

Fig. 96: Measuring Magnetic Clutch Clearance Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Connect the magnetic clutch lead wire to the positive (+) terminal of the battery. c. Check the clearance between the pressure plate and rotor when connecting the negative (-) terminal to the battery. Standard clearance: 0.5+/-0.15 mm (0.020+/-0.0059 in.) . If the clearance is not within the standard clearance, adjust the clearance using shims to obtain the standard clearance. Shim thickness: 0.1 mm (0.004 in.) 0.3 mm (0.012 in.) 0.5 mm (0.020 in.) . INSTALLATION 1. Install compressor : a. Install the compressor with the 3 bolts. Torque: 25 N.m (250 kgf.cm, 18 ft.lbf) . b. Connect the connector. 2. Connect discharge and suction hoses : a. Lubricate 2 new O-rings with compressor oil and install them to the hoses. NOTE: Hose should be connected immediately after the caps have been removed.

b. Connect the both hoses with the 2 bolts.Torque: 10 N.m (100 kgf.cm, 7 ft.lbf) . 3. INSTALL AND CHECK DRIVE BELT . See INSTALLATION and DRIVE BELT . 4. Connect negative (-) terminal cable to battery . 5. Evacuate air from refrigeration system charge system with refrigerant . Specified amount: 650+/-

2002 MANUAL A/C-HEATER SYSTEMS Air Conditioning - Corolla

50 g (22.93 +/- 1.76 oz.). 6. Inspect for leakage of refrigerant : Using a gas leak detector, check for leakage of refrigerant. If there is leakage, check the tightening torque at the joints. 7. Inspect A/C operation .

RECEIVER
ON-VEHICLE INSPECTION
Inspect Sight Glass, Fusible Plug And Fitting For Leakage

Using a gas leak detector, check for leakage of refrigerant. If there is leakage, check the tightening torque at the joints. REMOVAL 1. Discharge refrigerant from refrigeration system . 2. Remove liquid tube between condenser and receiver : a. Remove the nut from condenser. CAUTION: Cap the open fittings immediately to keep moisture or dirt out of the system.

2002 MANUAL A/C-HEATER SYSTEMS Air Conditioning - Corolla

Fig. 97: Locating Liquid Tube To Receiver Union Bolt & Condenser To Receiver Union Nut & Bolt Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the bolt and the liquid tube from receiver. CAUTION: Cap the open fittings immediately to keep moisture or dirt out of the system. 3. Disconnect liquid tube between receiver and cooling unit : Remove the bolt and disconnect the tube from receiver. 4. Remove receiver : Remove the bolts and receiver with holder.

2002 MANUAL A/C-HEATER SYSTEMS Air Conditioning - Corolla

Fig. 98: Locating Receiver Mounting Bolt Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSTALLATION 1. Install the receiver and receiver holder with the bolt.

2002 MANUAL A/C-HEATER SYSTEMS Air Conditioning - Corolla

Fig. 99: Locating Receiver Mounting Bolt Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. If receiver is replaced, add compressor oil to receiver. Add 20 cc (1.7 fl.oz.) compressor oil: NDOIL 8 or equivalent . 2. Connect liquid tube between receiver and cooling unit : a. Lubricate a new O-ring with compressor oil and install them to the tube. b. Connect the tube with the bolt. Torque: 5.4 N.m (55 kgf.cm, 48 in..lbf) . 3. Install liquid tube between condenser and receiver : a. Lubricate 2 new O-rings with compressor oil and install them to the tubes.

2002 MANUAL A/C-HEATER SYSTEMS Air Conditioning - Corolla

Fig. 100: Locating Liquid Tube To Receiver Union Bolt & Condenser To Receiver Union Nut & Bolt Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Install the liquid tube to receiver with the bolt. Torque: 5.4 N.m (55 kgf.cm, 48 in. lbf.) . c. Tighten the nut. Torque: 14 N.m (140 kgf.cm, 10 ft.lbf) . 4. Charge refrigerant from refrigeration system : a. Evacuate air from refrigeration system. b. Charge system with refrigerant and inspect for leakage of refrigerant. Specified amount: 650 +/- 50 g (22.93 +/- 1.76 oz.) .

CONDENSER
ON-VEHICLE INSPECTION NOTE: Be careful not to damage the fins.

1. Inspect condenser fins for blockage or damage . If the fins are clogged, wash them with water and dry with compressed air. If the fins are bent, straighten them with a screwdriver or pliers.

2002 MANUAL A/C-HEATER SYSTEMS Air Conditioning - Corolla

2. Inspect condenser and fittings for leakage : Using a gas leak detector, check for leakage of refrigerant. If there is leakage, check the tightening torque at the joints. REMOVAL 1. Discharge refrigerant from refrigeration system . 2. Remove receiver . See REMOVAL . CAUTION: Cap the open fittings immediately to keep moisture or dirt out of the system.

Fig. 101: Locating Condenser To Discharge Hose Union Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 3. Disconnect discharge hose : Remove the bolt and disconnect the hose. 4. Remove 2 upper radiator supports .

2002 MANUAL A/C-HEATER SYSTEMS Air Conditioning - Corolla

5. Remove No. 6 relay block set bolts .

Fig. 102: Locating No. 6 Relay Block & Upper Radiator Hoses Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE: 6. 7. 8. 9. It is not necessary to drain out all the coolant.

Drain engine coolant . Disconnect upper radiator hose . Disconnect engine coolant reservoir hose . Remove condenser : a. Lift up the radiator and push it toward engine.

2002 MANUAL A/C-HEATER SYSTEMS Air Conditioning - Corolla

Fig. 103: Removing Radiator Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the 2 condenser set bolts.

2002 MANUAL A/C-HEATER SYSTEMS Air Conditioning - Corolla

Fig. 104: Locating Condenser Set Bolts & Removing Condenser Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Pull the condenser toward radiator and pull it upward. INSTALLATION 1. Install condenser : a. Install the condenser. b. Install the 2 condenser set bolts. c. Mount the radiator and install the 2 upper radiator supports.

2002 MANUAL A/C-HEATER SYSTEMS Air Conditioning - Corolla

Fig. 105: Installing Condenser & Locating Condenser Set Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 2. Connect the upper radiator hose to the radiator .

2002 MANUAL A/C-HEATER SYSTEMS Air Conditioning - Corolla

Fig. 106: Locating No. 6 Relay Block & Upper Radiator Hoses Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 3. 4. 5. 6. Connect the engine coolant reservoir hose to the radiator . Fill with engine coolant . Install No. 6 relay block set bolts . Connect discharge hose : a. Lubricate a new O-ring with compressor oil and install them to the hose. b. Install the hose with the bolt. Torque: 10 N.m (100 kgf.cm, 7 ft.lbf) .

2002 MANUAL A/C-HEATER SYSTEMS Air Conditioning - Corolla

Fig. 107: Locating Condenser To Discharge Hose Union Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 7. Install receiver . See INSTALLATION . 8. Charge refrigerant from refrigeration system : a. Evacuate air from refrigeration system b. Charge system with refrigerant and inspect for leakage of refrigerant. Specified amount: 650 +/- 50 g (22.93 +/- 1.76 oz.) .

BLOWER MOTOR
INSPECTION 1. 2. 3. 4. Remove FRONT DOOR SCUFF PLATE RH . Remove COWL SIDE TRIM RH . Remove LOWER PANEL . Remove blower motor . a. Disconnect the blower motor connector. b. Using a torx wrench, remove the 3 screws and blower motor.

2002 MANUAL A/C-HEATER SYSTEMS Air Conditioning - Corolla

Fig. 108: Locating Blower Motor Mounting Bolts & Connector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 5. Inspect blower motor operation : Connect the positive (+) lead from the battery to terminal 1 and negative (-) lead to terminal 2, then check that the motor operations smoothly. If operation is not as specified, replace the blower motor.

2002 MANUAL A/C-HEATER SYSTEMS Air Conditioning - Corolla

Fig. 109: Testing Blower Motor Operation Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 6. Install blower motor : a. Using a torx wrench, install the blower motor with the 3 screws.

2002 MANUAL A/C-HEATER SYSTEMS Air Conditioning - Corolla

Fig. 110: Locating Blower Motor Mounting Bolts & Connector Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Connect the blower motor connector. 7. Install LOWER PANEL . 8. Install COWL SIDE TRIM RH 9. Install FRONT DOOR SCUFF PLATE RH .

BLOWER RESISTOR
INSPECTION 1. 2. 3. 4. Remove FRONT DOOR SCUFF PLATE RH . Remove COWL SIDE TRIM RH . Remove LOWER PANEL . Remove blower resistor : a. Disconnect the connector. b. Remove the 2 screws and blower resistor.

2002 MANUAL A/C-HEATER SYSTEMS Air Conditioning - Corolla

Fig. 111: Locating Blower Resistor Mounting Screws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 5. Inspect resistance .

Fig. 112: Blower Resistor Specifications Chart Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 MANUAL A/C-HEATER SYSTEMS Air Conditioning - Corolla

Fig. 113: Identifying Blower Resistor Terminals Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. If the resistance is not as specified, replace the blower resistor. 6. Install blower resistor : a. Install the blower resistor with the 2 screws.

2002 MANUAL A/C-HEATER SYSTEMS Air Conditioning - Corolla

Fig. 114: Locating Blower Resistor Mounting Screws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Connect the connector. 7. Install LOWER PANEL . 8. Install COWL SIDE TRIM RH . 9. Install FRONT DOOR SCUFF PLATE RH .

AIR INLET SERVOMOTOR

REMOVAL 1. Remove blower unit . See REMOVAL . 2. Remove the 3 screws and air inlet servomotor with link .

2002 MANUAL A/C-HEATER SYSTEMS Air Conditioning - Corolla

Fig. 115: Locating Servomotor Mounting Screws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSPECTION
Inspect Air Inlet Servomotor

Inspect the servomotor operation. 1. Connect the positive (+) lead of the battery to terminal 5 and negative (-) lead to terminal 2.

2002 MANUAL A/C-HEATER SYSTEMS Air Conditioning - Corolla

Fig. 116: Testing Air Inlet Servomotor Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 2. Check the motor arm rotates counterclockwise and arm stops on the "FRESH" position. 3. Connect the positive (+) lead of the battery to terminal 5 and negative (-) lead to terminal 1.

2002 MANUAL A/C-HEATER SYSTEMS Air Conditioning - Corolla

4. Check the motor arm rotates counterclockwise and arm stops on the "RECIRC" position. If operations are not as specified, replace the air inlet servomotor. INSTALLATION 1. Install blower unit . See INSTALLATION . 2. Install the air inlet servomotor with the 3 screws .

Fig. 117: Locating Servomotor Mounting Screws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

PRESSURE SWITCH
ON-VEHICLE INSPECTION 1. Set on manifold gauge set . See MANIFOLD GAUGE SET .

2002 MANUAL A/C-HEATER SYSTEMS Air Conditioning - Corolla

Fig. 118: Locating Pressure Switch & Identifying Pressure Switch Terminals Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 2. Disconnect connector from pressure switch . 3. Run engine at approx. 2,000 RPM . 4. Magnetic Clutch Control: Inspect pressure switch operation : a. Connect the positive (+) lead from the ohmmeter to terminal 4 and the negative (-) lead to terminal 1.

2002 MANUAL A/C-HEATER SYSTEMS Air Conditioning - Corolla

Fig. 119: Pressure Switch Pressure To Continuity Graph (Magnetic Clutch Control) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Check continuity between terminals when refrigerant pressure is changed, as shown in the illustration. If operation is not as specified, replace the pressure switch. 5. Condenser Fan Control: inspect pressure switch operation : a. Connect the positive (+) lead from the ohmmeter to terminal 2 and the negative (-) lead to terminal 3.

2002 MANUAL A/C-HEATER SYSTEMS Air Conditioning - Corolla

Fig. 120: Pressure Switch Pressure To Continuity Graph (Condenser Fan Control) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Check continuity between terminals when refrigerant pressure is changed, as shown in the illustration. If operation is not as specified, replace the pressure switch. 6. Stop engine and set off manifold gauge set . 7. Connect connector to pressure switch . REMOVAL 1. Discharge refrigerant from refrigeration system . CAUTION: Lock the switch mount on the tube with an open end wrench, being careful not to deform the tube, and remove the switch.

2002 MANUAL A/C-HEATER SYSTEMS Air Conditioning - Corolla

Fig. 121: Removing Pressure Switch Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 2. Disconnect the connector and remove the pressure switch from liquid tube . Torque: 10 N.m (100 kgf.cm, 7 ft.lbf) . INSTALLATION 1. Install pressure switch to liquid tube : a. Lubricate a new O-ring with compressor oil and install them to the switch.

2002 MANUAL A/C-HEATER SYSTEMS Air Conditioning - Corolla

Fig. 122: Installing Pressure Switch Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Install the pressure switch. Torque: 10 N.m (100 kgf.cm, 7 ft.lbf) . c. Connect the connector. 2. Charge refrigerant to refrigeration system : a. Evacuate air from refrigeration system. b. Charge system with refrigerant and inspect for leakage of refrigerant. Specified amount: 650 +/- 50 g (22.93 +/- 1.76 oz.) .

HEATER MAIN RELAY

INSPECTION 1. Remove heater main relay (Marking: HTR) from relay block No. 6 .

2002 MANUAL A/C-HEATER SYSTEMS Air Conditioning - Corolla

Fig. 123: Locating Heater Main Relay Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 2. Inspect hater main relay continuity :

Fig. 124: Heater Main Relay Specifications Chart Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 MANUAL A/C-HEATER SYSTEMS Air Conditioning - Corolla

Fig. 125: Identifying Heater Main Relay Terminals & Wiring Diagram Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. If continuity is not as specified, replace the relay.

MAGNETIC CLUTCH RELAY

INSPECTION 1. Remove magnetic clutch relay (Marking: A.C MG) from relay block No. 5 .

2002 MANUAL A/C-HEATER SYSTEMS Air Conditioning - Corolla

Fig. 126: Locating Magnetic Clutch Relay Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 2. Inspect magnetic clutch relay continuity .

Fig. 127: Magnetic Clutch Relay Specifications Chart Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 MANUAL A/C-HEATER SYSTEMS Air Conditioning - Corolla

Fig. 128: Identifying Magnetic Clutch Relay Terminals & Wiring Diagram Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. If continuity is not as specified, replace the relay.

COOLING FAN RELAY

INSPECTION 1. Remove cooling fan relay no. 2 (Marking: A.C FAN No. 2) from relay block No. 5 .

2002 MANUAL A/C-HEATER SYSTEMS Air Conditioning - Corolla

Fig. 129: Locating Cooling Fan Relay No. 2 Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 2. Inspect No. 2 cooling fan relay continuity :

Fig. 130: Cooling Fan Relay No. 2 Specifications Chart Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 MANUAL A/C-HEATER SYSTEMS Air Conditioning - Corolla

Fig. 131: Identifying Cooling Fan Relay No. 2 Terminals & Wiring Diagram Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. If continuity is not as specified, replace the relay 3. Remove cooling fan relay No. 3 (Marking: A.C FAN No. 3) from relay block No. 5 .

2002 MANUAL A/C-HEATER SYSTEMS Air Conditioning - Corolla

Fig. 132: Locating Cooling Fan Relay No. 3 Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 4. Inspect No. 3 cooling fan relay continuity .

Fig. 133: Cooling Fan Relay No. 3 Specifications Chart Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 MANUAL A/C-HEATER SYSTEMS Air Conditioning - Corolla

Fig. 134: Identifying Cooling Fan Relay No. 3 Terminals & Wiring Diagram Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. If continuity is not as specified, replace the relay

CONDENSER FAN
ON-VEHICLE INSPECTION 1. Inspect the fan operation, as shown in the chart below . Test conditions:

Ignition switch ON. Blower speed control switch at "HI" position. Temperature control dial at "COOL" position Set on manifold gauge set. A/C switch ON.

2002 MANUAL A/C-HEATER SYSTEMS Air Conditioning - Corolla

Fig. 135: Condenser Fan Specifications Chart Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. If operation is not as specified, proceed to the next inspection. 2. Inspect condenser fan motor operation : a. Disconnect the fan connector.

2002 MANUAL A/C-HEATER SYSTEMS Air Conditioning - Corolla

Fig. 136: Locating Condenser Fan Motor Connector & Identifying Terminals Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Connect battery and ammeter. c. Check that the fan rotates smoothly and then check that the reading on the ammeter. Specified amperage: 5.2-8.2 A . If operation is not as specified, replace the fan motor. If operation is as specified, check the pressure switch, cooling fan relays and engine coolant temp. switch. COMPONENTS

2002 MANUAL A/C-HEATER SYSTEMS Air Conditioning - Corolla

Fig. 137: Identifying Condenser Fan Components Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL NOTE: It is not necessary to drain out all the coolant.

1. Drain engine coolant from radiator . 2. Disconnect upper radiator hose from radiator .

2002 MANUAL A/C-HEATER SYSTEMS Air Conditioning - Corolla

3. Disconnect reservoir hose from radiator . 4. Remove condenser fan : a. Disconnect the connectors. b. Remove the 5 bolts and fan. DISASSEMBLY 1. Remove the 2 nuts and both fans . 2. Remove fan motor : a. Disconnect the lead wire from the fan shroud. b. Remove the 6 screws and both fan motors. REASSEMBLY 1. Install fan motor : a. Install the both fan motor with the 6 screws. b. Connect the lead wire to the fan shroud. 2. Install the both fans with the 2 nuts . INSTALLATION 1. Install condenser fan : a. Install the fan with the 5 bolts. b. Connect the connectors. 2. Connect reservoir hose to radiator . 3. Connect upper radiator hose to radiator . 4. Fill with engine coolant to radiator .

AIR CONDITIONING CONTROL ASSEMBLY

ON-VEHICLE INSPECTION
Inspect A/C Control Dial And Lever Operation

Move the control dials and lever left and light and check for stiffness and binding through the full range of the levers. COMPONENTS

2002 MANUAL A/C-HEATER SYSTEMS Air Conditioning - Corolla

Fig. 138: Identifying A/C Control Dial & Lever Components Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REMOVAL 1. 2. 3. 4. 5. 6. 7. 8. Remove cowl side trims . Remove front door scuff plates . Remove lower finish panel . Remove Lower Insert Panel . Remove Center Cluster Finish Panel . Remove heater to resistor No. 2 duct . Remove lower panel . Remove rear console box .

2002 MANUAL A/C-HEATER SYSTEMS Air Conditioning - Corolla

9. Remove shifting hole bezel . 10. Remove finish lower center panel . 11. Disconnect heater control cable .

Fig. 139: Locating Air Mix & Model Control Cables & Clips Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE: Be careful not to vent the mode control cable, when pull out the A/C control assembly.

2002 MANUAL A/C-HEATER SYSTEMS Air Conditioning - Corolla

Fig. 140: Locating A/C Control Assembly Mounting Screws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 12. Remove the 2 screws and pull out the A/C control assembly, then disconnect the connector . DISASSEMBLY 1. 2. 3. 4. Pull out heater control knobs . Release the 4 screws and remove the heater control name plate . Release the 4 clews and remove the A/C switch from the heater control name plate . Remove blower speed control switch : a. Pull out the 2 bulbs. b. Disconnect the 2 bulb holders. c. Remove the 2 screws and blower speed control switch. NOTE: Tape the screwdriver tip before use.

5. Remove heater control cables : a. Using a screwdriver, open the claw of the cable clamp and disconnect the outer cables. b. Remove the inner cables from the A/C control assembly. INSPECTION

2002 MANUAL A/C-HEATER SYSTEMS Air Conditioning - Corolla

1. A/C Switch , inspect A/C indicator operation: a. Connect the positive (+) lead from the battery to terminal 6 and negative (-) lead to terminal 4.

Fig. 141: Inspecting A/C switch operation (1 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Push the button in and check that the A/C indicator lights up. If operation is not as specified, replace the A/C switch. c. Connect the positive (+) lead from the battery to terminal 3 and check that the indicator dims.

2002 MANUAL A/C-HEATER SYSTEMS Air Conditioning - Corolla

Fig. 142: Inspecting A/C switch operation (2 Of 2) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. If operation is not as specified, replace the A/C switch. 2. W/ A/C Models , inspect A/C switch continuity:

2002 MANUAL A/C-HEATER SYSTEMS Air Conditioning - Corolla

Fig. 143: Identifying A/C Switch Mode Settings & Terminals Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 144: A/C Switch Mode Specifications Chart Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. If continuity is not as specified, replace the A/C switch.

2002 MANUAL A/C-HEATER SYSTEMS Air Conditioning - Corolla

3. Inspect fresh/recirc switch indicator operation : a. Connect the positive (+) lead from the battery to terminal 1 and negative (-) lead to terminal 8.

Fig. 145: Identifying Fresh/Recirc Switch Indicator Test Mode Settings & Terminals Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Push the fresh/recirc switch in and check that the indicator lights up. If operation is not as specified, replace the fresh/recirc switch. 4. Inspect dimming operation : a. Connect the positive (+) lead from the battery to terminal 1 and negative (-) lead to terminal 8.

2002 MANUAL A/C-HEATER SYSTEMS Air Conditioning - Corolla

Fig. 146: Identifying Dimming Switch Mode Settings & Terminals Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Push the fresh/ recirc switch, then the indicator lights up. c. Connect the positive (+) lead from the battery to terminal 5 and then check that the indicator dims. If operation is not as specified, replace the fresh/ recirc switch. 5. Inspect fresh/recirc switch continuity :

2002 MANUAL A/C-HEATER SYSTEMS Air Conditioning - Corolla

Fig. 147: Identifying Fresh/Recirc Switch Continuity Test Mode Settings & Terminals Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 148: Fresh/Recirc Switch Continuity Specifications Chart Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. If continuity is not as specified, replace the fresh/recirc switch. 6. Defroster, Def-foot and foot mode switch , inspect fresh/recirc switch indicator operation: a. Connect the positive (+) lead from the battery to terminal 1 and negative (-) lead to terminal 8.

2002 MANUAL A/C-HEATER SYSTEMS Air Conditioning - Corolla

Fig. 149: Identifying Fresh/Recirc Switch Defroster, Def-Foot & Foot Mode Switch Settings & Terminals Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Turn the mode dial to the "DEF", "DEF-FOOT" and "FOOT" position and check that the fresh/recirc switch indicator lights off. If operation is not as specified, replace the fresh/recirc switch. 7. Inspect blower speed control switch continuity :

2002 MANUAL A/C-HEATER SYSTEMS Air Conditioning - Corolla

Fig. 150: Identifying Blower Speed Control Switch Settings & Terminals Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 151: Blower Speed Control Switch Continuity Specifications Chart Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Switch continuity : If continuity is not as specified, replace the blower speed control switch. Illumination circuit : If continuity is not as specified, replace the bulb. REASSEMBLY

2002 MANUAL A/C-HEATER SYSTEMS Air Conditioning - Corolla

1. Install heater control cables : a. Install the inner cables to the A/C control assembly. b. Connect the outer cables. 2. Install blower speed control switch : a. Install the blower speed control switch with the 2 screws. b. Connect the 2 bulb holders. c. Push in the 2 bulbs. 3. Install the A/C switch to the heater control name plate . 4. Install the heater control name plate . 5. Push in heater control knobs . INSTALLATION 1. Install A/C control assembly : a. Connect the connector. b. Pass the heater control cables as shown in the illustration.

Fig. 152: Locating Air Mix & Model Control Cables & Clips Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Install the 2 set screws.

2002 MANUAL A/C-HEATER SYSTEMS Air Conditioning - Corolla

2. Connect heater control cables : a. Set the temperature control dial at "MAX. COOL" position

Fig. 153: Locating A/C Control Assembly Mounting Screws Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Set the mode control dial at "DEF" position. NOTE: Lock the clamp while lightly pulling the outer cable to the direction shown by arrow in the illustration.

2002 MANUAL A/C-HEATER SYSTEMS Air Conditioning - Corolla

Fig. 154: Adjusting Air Mix Control Cable Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Adjust the air mix control cable. Set the air mix damper control lever to "MAX. COOL" position and connect the inner cable to lever pin and clamp the outer cable. NOTE: Lock the clamp while lightly pushing the outer cable to the direction shown by arrow in the illustration.

2002 MANUAL A/C-HEATER SYSTEMS Air Conditioning - Corolla

Fig. 155: Adjusting Mode Control Cable Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. d. Adjust the mode control cable: Pull the air inlet control link to "DEF" position and connect the control cable and lock the clamp. Install finish lower center panel . Install shifting hole bezel . Install rear console box . Install lower panel . Install heater to register No. 2 duct . Install center cluster finish panel . Install lower insert panel . Install lower finish panel . Install front door scuff plates . Install cowl side trims .

3. 4. 5. 6. 7. 8. 9. 10. 11. 12.

AIR CONDITIONING AMPLIFIER

ON-VEHICLE INSPECTION
Inspect Amplifier Circuit

2002 MANUAL A/C-HEATER SYSTEMS Air Conditioning - Corolla

a. Remove lower panel .

Fig. 156: Identifying Air Conditioning Amplifier Terminals (Wire Harness Side) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Disconnect the connector and inspect the connector on wire harness side, as shown in the chart below. Test conditions:

Ignition switch ON Blower speed control switch at "HI" position

Fig. 157: Air Conditioning Amplifier Terminal Specifications (Wire Harness Side) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. If circuit is as specified, try to replace the amplifier with a new one. If the circuit is not as specified, inspect the circuits connected to other parts.

2002 MANUAL A/C-HEATER SYSTEMS Air Conditioning - Corolla

c. Connect the connector to amplifier and inspect wire harness side connector from the back side, as shown in the chart below.

Fig. 158: Identifying Air Conditioning Amplifier Terminals (Back Side) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Test conditions:

Running engine at idle speed Blower speed control switch at "HI" position A/C switch ON Temperature control dial at "MAX. COOL" position Set on manifold gauge set

2002 MANUAL A/C-HEATER SYSTEMS Air Conditioning - Corolla

Fig. 159: Air Conditioning Amplifier Terminal Specifications (Back Side) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. If circuit is as specified, try to replace the amplifier with a new one. If the circuit is not as specified, inspect the circuits connected to other parts. REMOVAL 1. 2. 3. 4. Remove FRONT DOOR SCUFF PLATE RH . Remove COWL SIDE TRIM RH . Remove LOWER PANEL . Remove amplifier : a. Disconnect the connector.

2002 MANUAL A/C-HEATER SYSTEMS Air Conditioning - Corolla

Fig. 160: Locating A/C Amplifier & Mounting Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Remove the 2 bolts and amplifier. INSTALLATION 1. Install amplifier : a. Install the amplifier with the 2 bolts.

2002 MANUAL A/C-HEATER SYSTEMS Air Conditioning - Corolla

Fig. 161: Locating A/C Amplifier & Mounting Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. b. Connect the connector. 2. Install LOWER PANEL 3. Install COWL SIDE TRIM RH 4. Install FRONT DOOR SCUFF PLATE RH .

ENGINE COOLANT TEMPERATURE (ECT) SWITCH

INSPECTION
Inspect ECT Switch Continuity

a. Using an ohmmeter, check no continuity exists between terminals when the coolant temperature is above 90C (194F).

2002 MANUAL A/C-HEATER SYSTEMS Air Conditioning - Corolla

Fig. 162: Testing ECT Switch Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. If continuity exists, replace the switch. b. Using an ohmmeter, check continuity exists between terminals when the coolant temperature is below 83C (181F). If no continuity exists, replace the switch.

SPECIFICATIONS
SPECIFICATIONS Application Compressor Type Compressor Belt Tension Compressor Oil Capacity (3) Condenser Oil Capacity (3) Evaporator Oil Capacity (3) Receiver Oil Capacity (3) Specification
(1) (2)

4.1 ozs. 1.4 ozs. 1.4 ozs. 1.7 oz.

2002 MANUAL A/C-HEATER SYSTEMS Air Conditioning - Corolla

Refrigerant (R-134a) Capacity System Operating Pressures (4) High Side Low Side
(1) Information is not available from manufacturer. (2) Automatic belt tensioner is used. Adjustment is not required. (3) Use ND-OIL 8 refrigerant oil or equivalent.

21.2-24.7 ozs. 199-213 psi (14-15 kg/cm2 ) 21-36 psi (1.5-2.5 kg/cm2 )

(4) With ambient temperature at 86-95F (30-50C) at air inlet with switch in RECIRC position,

engine at 2000 RPM, blower switch in HI position and temperature control dial in COOL position.

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS Application Compressor Mounting Bolt Clutch Pressure Plate-To-Compressor Shaft Bolt Expansion Valve Mounting Bolt Hose Connection Bolts Condenser To Discharge Hose Condenser To Liquid Tube Compressor To Discharge Hose Compressor To Suction Hose Receiver To Liquid Tube Pressure Switch Ft. Lbs. (N.m) 18 (24) INCH Lbs. (N.m) 117 (13.2) 48 (5.4) 88 (10) 124 (14) 88 (10) 88 (10) 48 (5.4) 88 (10)

WIRING DIAGRAMS
For wiring diagrams, see AIR CONDITIONING in SYSTEM WIRING DIAGRAMS under ELECTRICAL.

2002 SUSPENSION Front - Corolla

2002 SUSPENSION Front - Corolla

DESCRIPTION
Vehicles are equipped with front wheel drive and independent MacPherson strut (shock absorber) front suspension. Suspension consists of vertically mounted strut assemblies, control arms, and stabilizer bar. Shock absorbers are mounted between inner fender and steering knuckle. Tie rod ends connect rack and pinion steering to steering knuckle. Ball joint connects steering knuckle to lower control arm. A stabilizer bar attaches to lower control arms.

ADJUSTMENTS & INSPECTION

WHEEL ALIGNMENT SPECIFICATIONS & PROCEDURES NOTE: See SPECIFICATIONS & PROCEDURES article in WHEEL ALIGNMENT.

BALL JOINT INSPECTION NOTE: Ball joint must be removed for the following inspection procedure. See LOWER CONTROL ARM and BALL JOINTS under REMOVAL & INSTALLATION.

Remove ball joint and place in vise, with ball joint stud pointing upward. Flip stud back and forth about 5 times. Reinstall ball joint nut. Place torque wrench on ball joint nut and turn nut continuously 1 turn every 2 to 4 seconds. Read torque measurement on 5th turn. See BALL JOINT TURNING TORQUE SPECIFICATIONS table. If torque is not within specification, replace ball joint. BALL JOINT TURNING TORQUE SPECIFICATIONS Application Corolla WHEEL BEARING INSPECTION NOTE: Wheel bearings are not adjustable. Whenever bearings are removed, replace with NEW bearings, races and oil seals.

INCH Lbs. (N.m) 8.7-26 (1-2.9)

1. Remove front wheel. Remove brake caliper and disc. Support caliper out of way. Using dial indicator placed near center of axle hub, check backlash by moving hub in bearing shaft direction. If backlash exceeds .002 in. (.05 mm), replace bearing. 2. Check deviation at axle hub surface, outside of hub bolt by moving hub with twisting motion. If deviation is more than .002 in. (.05 mm), replace bearing. Reinstall disc, brake caliper and front wheel. See Fig. 1 .

2002 Toyota Corolla LE

2002 SUSPENSION Front - Corolla

Fig. 1: Identifying Hub Components Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

REMOVAL & INSTALLATION

FRONT AXLE HUB & WHEEL BEARING
Removal

1. Remove front wheel. Check wheel bearing backlash and deviation (rotational free play). See WHEEL BEARING INSPECTION under ADJUSTMENTS & INSPECTION. 2. Remove cotter pin and lock nut cap. Hold drive shaft from turning by applying brakes and remove drive shaft lock nut. Remove brake caliper and disc and support caliper out of way. 3. Remove ABS speed sensor and wire harness clamp. Remove brake hose from shock absorber clamp. Loosen 2 nuts on lower end of shock absorber (DO NOT remove). 4. Remove cotter pin and nut from tie rod end. Use separator tool to disconnect tie rod end from steering knuckle. 5. Remove 2 nuts and 1 bolt and disconnect lower ball joint from lower control arm. Remove 2 nuts and bolts from lower end of shock absorber. Remove steering knuckle and axle hub from vehicle. See Fig. 1. 6. Mount assembly in vise. Carefully pry dust deflector from hub. Remove cotter pin and nut, and use separator tool to remove lower ball joint from hub assembly. Remove inner oil seal from hub. Remove inner snap ring. 7. Use slide hammer and attaching plate to remove axle hub. Place axle hub on press and use appropriate support plates to press inner bearing race from axle hub. Remove Torx bolts and remove dust cover. 8. Use a suitable extractor to remove outer oil seal from hub. Remove wheel bearing snap ring, if equipped. Place inner race against outside of bearing and press wheel bearing from axle hub. See Fig.

2002 Toyota Corolla LE

2002 SUSPENSION Front - Corolla

1.
Installation

To install, reverse removal procedure. Use NEW snap ring after pressing in NEW wheel bearing. Use NEW cotter pins. Tighten bolts to specifications. See TORQUE SPECIFICATIONS . SHOCK ABSORBER
Removal & Installation

1. Remove front wheel. Disconnect brake hose and ABS speed sensor clamp from shock absorber. 2. Remove 2 lower shock absorber nuts and bolts and disconnect shock absorber from steering knuckle. See Fig. 2 . Remove 3 upper shock absorber mounting nuts from inside engine compartment and remove shock absorber with coil spring. 3. To install, reverse removal procedure. Tighten bolts and nuts to specification. See TORQUE SPECIFICATIONS .

2002 Toyota Corolla LE

2002 SUSPENSION Front - Corolla

Fig. 2: Exploded View Of Front Suspension Components Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. LOWER CONTROL ARM
Removal & Installation

1. Remove front wheel. Remove stabilizer bar. See STABILIZER BAR . Remove 2 nuts and bolt and

2002 Toyota Corolla LE

2002 SUSPENSION Front - Corolla

disconnect lower control arm from lower ball joint. See Fig. 3 . 2. On A/T models, remove 3 bolts, lower control arm bracket and lower control arm from right side. On left side, support suspension crossmember. Remove 7 bolts and 4 nuts, and then remove lower control arm bracket and suspension crossmember with lower control arm attached. See Fig. 4 . Remove lower control arm-to-crossmember bolt on left side. 3. On M/T, remove 6 bolts (3 each side) from lower control arm bracket and lower control arms. See Fig. 3 . 4. To install, reverse removal procedure. Tighten all bolts and nut to specification. See TORQUE SPECIFICATIONS .

2002 Toyota Corolla LE

2002 SUSPENSION Front - Corolla

Fig. 3: Exploded View Of Front Suspension Crossmember Components & Stabilizer Bar Components Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 Toyota Corolla LE

2002 SUSPENSION Front - Corolla

Fig. 4: Location Of Suspension Crossmember Bolts & Nuts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. BALL JOINTS
Removal & Installation

1. Remove steering knuckle with axle hub. See FRONT AXLE HUB & WHEEL BEARING . Using screwdriver, pry off dust cover. Remove cotter pin and nut. Use ball joint removal tool to remove lower ball joint from axle hub assembly. 2. To install, reverse removal procedure. Check ball joint turning torque. See BALL JOINT CHECKING under ADJUSTMENTS & INSPECTION. Install NEW cotter pin and NEW dust cover. STABILIZER BAR
Removal & Installation

1. Remove both front wheels. Remove 4 nuts and remove both stabilizer bar links (2 nuts at each end). See LOWER CONTROL ARM . Remove left and right stabilizer bar brackets and bushings. 2. Remove suspension brace. See Fig. 4 . Remove 2 bolts, bracket and bushing. Install bushing, with cut out facing toward rear, on inside of paint line on stabilizer bar. Remove stabilizer bar. 3. To install, reverse removal procedure. Tighten all bolts and nuts to specification. See Fig. 3 .

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS Application Brace Mounting Nuts Brake Caliper Mounting Bolts-To-Steering Knuckle Brake Hose Clamp Bolt Ft. Lbs. (N.m) 51 (69) 65 (88) 22 (30)

2002 Toyota Corolla LE

2002 SUSPENSION Front - Corolla

Drive Axle Nut Lower Ball Joint-To-Steering Knuckle Lower Control Arm-To-Ball Joint Nuts & Bolt Lower Control Arm Bracket Bolts & Nuts Front Bracket-To-Bracket Bolt Lower Bracket (Rear)-To-Upper Bracket (Center) Bolt Lower Bracket-To-Upper Bracket Nut Upper Bracket Center Bolt Upper Bracket Outer (Short) Bolt Lower Control Arm Bushing-To-Suspension Crossmember Bolts Shock Absorber Center Nut Shock Absorber Lower Nuts Shock Absorber Upper Nuts Stabilizer Bar Link Nuts Suspension Crossmember Mounting Bolts (1) Outer Rear Bolts ("A") Front Bolts ("B") Outer End Bolts ("C") Rear Bolts ("D") ("E") Tie Rod End Nut ABS Speed Sensor Bolt Axle Hub Dust Cover Bolts (1) See Fig. 4 .

166 (225) 91 (123) 105 (142 167 (226) 109 (148) 14 (19) 129 (175) 108 (147) 158 (214) 35 (47) 202 (274) 29 (39) 33 (45) 129 (175) 167 (226) 109 (148) 45 (61) 42 (57) 36 (49) INCH Lbs. (N.m) 71 (8.0) 74 (8.3)

2002 Toyota Corolla LE

2002 SUSPENSION Rear - Corolla

2002 SUSPENSION Rear - Corolla

DESCRIPTION
Rear suspension components are strut assemblies or shock absorbers with coil springs, connected between rear axle carrier or lower suspension arm, and vehicle body. Wheel bearing and axle hub is a one piece assembly, bolted to rear axle carrier. See Fig. 1 .

Fig. 1: Identifying Rear Suspension Components Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

ADJUSTMENTS & INSPECTION

WHEEL ALIGNMENT SPECIFICATIONS & PROCEDURES NOTE: See SPECIFICATIONS & PROCEDURES in WHEEL ALIGNMENT article.

2002 Toyota Corolla LE

2002 SUSPENSION Rear - Corolla

WHEEL BEARING INSPECTION Raise and support vehicle. Remove wheel and brake drum. Position dial indicator with stem against center of axle hub. Move axle hub in and out while observing dial indicator. Replace hub if axial play exceeds .002 in. (.05 mm). Measure hub axial runout. Replace hub if runout exceeds .0028 in. (.07 mm). WHEEL BEARING ADJUSTMENT Hubs must be replaced if axle end play or runout are not within specification. No adjustment is available. See WHEEL BEARINGS (HUBS) under REMOVAL & INSTALLATION

REMOVAL & INSTALLATION

AXLE HUB & CARRIER
Removal

1. Raise and support vehicle. Remove rear wheels. Disconnect rear ABS speed sensor. See Fig. 2 . Disconnect brakeline from flex hose, and plug openings. Remove brake drum. Remove 4 axle hub-tocarrier bolts, axle hub and "O" ring. 2. Note position of nuts on suspension arms and strut rods for installation reference. Disconnect strut rod from axle carrier. Disconnect No. 1 and No. 2 lower suspension arms from axle carrier. Remove 2 bolts and nuts, and remove axle carrier.

Fig. 2: Exploded View Of Rear Axle Hub & Carrier Components

2002 Toyota Corolla LE

2002 SUSPENSION Rear - Corolla

Installation

To install, reverse removal procedure. Coat NEW "O" ring with grease and install hub. Tighten all fasteners to specification. See TORQUE SPECIFICATIONS . Bleed brake system. Check rear wheel alignment. NOTE: Bounce vehicle several times to stabilize suspension. Tighten axle carrier-toshock absorber assembly and suspension arm bolts to specification with vehicle at normal operating height.

STABILIZER BAR
Removal

1. Raise and support vehicle. Remove rear wheels. Disconnect flexible brake hoses mounted on shock absorbers. Remove the clips and plug openings. Disconnect shock absorbers from rear axle carrier. See Fig. 3 . 2. Using a jack and wooden block, support fuel tank and disconnect both fuel tank mounting bands. Lower fuel tank. Disconnect left and right stabilizer bar links from stabilizer bar. Remove stabilizer bar brackets and bushings. Remove stabilizer bar.

Fig. 3: Identifying Rear Stabilizer Bar Components Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Installation

To install, reverse removal procedure. Install stabilizer bar bushings to outside of paint line on stabilizer bar. See Fig. 4 . Tighten all nuts and bolts to specification. See TORQUE SPECIFICATIONS .

2002 Toyota Corolla LE

2002 SUSPENSION Rear - Corolla

Fig. 4: Installing Stabilizer Bar Bushings Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. SHOCK ABSORBER
Removal

1. Raise and support vehicle. Remove rear wheels. Remove flexible brake hose and ABS speed sensor harness clamps from struts/shock absorbers. Disconnect left and right stabilizer bar links from struts. See Fig. 5 . On models with a one-piece rear seat, remove rear seatback and cushion. On models with separated rear seat, lean rear seatback forward. NOTE: If strut is to be disassembled, loosen but do not remove strut shaft nut before removing strut.

2. Using 2 floor jacks, support rear axle carriers. Remove strut or shock absorber lower mounting nuts/bolts. Remove the cap and strut-to-body upper mounting nuts. Remove strut or shock absorber.

2002 Toyota Corolla LE

2002 SUSPENSION Rear - Corolla

Fig. 5: Exploded View Of Rear Shock Absorber Components Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Inspection

Compress and extend shock/strut shaft to check for abnormal resistance or noise. Push shaft in fully, and release. Shaft should return at a constant speed throughout its travel. If shock/strut is defective, replace as an assembly. CAUTION: To prevent personal injury, discharge gas from old shock absorber

2002 Toyota Corolla LE

2002 SUSPENSION Rear - Corolla

prior to disposal. Carefully drill a hole 0.08-0.12 in. (2-3 mm) in diameter above lower mounting bracket on cylinder.
Installation

To install, reverse removal procedure. Tighten all fasteners to specification. See TORQUE SPECIFICATIONS . STRUT ROD
Removal & Installation

1. Raise and support vehicle. Remove rear wheels. Remove center exhaust pipe. Remove nuts and bolts holding strut rod to axle carrier and body. Remove strut rod. 2. Install strut rod, leaving nuts and bolts loose. Lower vehicle. Bounce vehicle several times to settle suspension. With vehicle weight on suspension, tighten all nuts and bolts to specification. See TORQUE SPECIFICATIONS . SUSPENSION ARMS
Removal

NOTE:

Note orientation of suspension arm installation for reassembly reference.

1. Raise and support vehicle. Remove rear wheels. Remove the 2 nuts and suspension arm washer. See Fig. 1 . Remove No. 2 suspension arm from axle carrier. Remove stabilizer bar brackets from suspension member. 2. Using a floor jack, support suspension member. Remove suspension member nuts, bolts and stoppers. Lower suspension member. Remove No. 1 lower suspension arm.
Installation

1. To install, reverse removal procedure. Be sure to install components in their original locations. Suspension arms have left hand threads on one side. Install suspension arms with left hand threads to the axle carrier side. 2. Install all nuts and bolts, but DO NOT tighten. Install wheels. Lower vehicle. Bounce vehicle several times to stabilize suspension. Tighten all nuts and bolts to specification, with vehicle weight on suspension. See TORQUE SPECIFICATIONS . Check rear wheel alignment. See WHEEL ALIGNMENT SPECIFICATIONS & PROCEDURES in ADJUSTMENTS & INSPECTION. WHEEL BEARINGS (HUB)
Removal

NOTE:

Wheel bearing and hub is a one piece assembly and must be replaced as a unit. See Fig. 2 .

1. Raise and support vehicle. Remove rear wheels. Remove brake drum. Disconnect ABS sensor. 2. Check wheel hub axial play and runout. See WHEEL BEARING INSPECTION under

2002 Toyota Corolla LE

2002 SUSPENSION Rear - Corolla

ADJUSTMENTS & INSPECTION. Remove 4 bolts and remove axle hub and "O" ring.
Installation

Coat NEW "O" ring with grease and install hub. To complete installation, reverse removal procedure. Tighten all nuts and bolts to specification. See TORQUE SPECIFICATIONS .

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS Application Axle Hub-To-Axle Carrier Bolts Brake Caliper-To-Backing Plate Bolts Stabilizer Bar Bracket Bolts Stabilizer Bar Link Nuts Strut Rod Bolts Strut Shaft Nut Strut-To-Axle Carrier Bolts & Nuts Strut-To-Body Nuts Suspension Arm-To-Axle Carrier Bolt Suspension Arm-To-Suspension Member Bolt & Nut Wheel Lug Nut ABS Speed Sensor Bolt Ft. Lbs. (N.m) 59 (80) 35 (47) 14 (19) 32 (44) 67 (91) 36 (49) 105 (142) 29 (39) 92 (125) 92 (125) 76 (103) INCH Lbs. (N.m) 48 (5.4)

2002 Toyota Corolla LE

2002 WHEEL ALIGNMENT Specifications & Procedures

COROLLA
PROCEDURES
Front Wheel Alignment

1. Measure vehicle height .

2002 Toyota Corolla LE

2002 WHEEL ALIGNMENT Specifications & Procedures

Fig. 95: Measuring Vehicle Height Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 Toyota Corolla LE

2002 WHEEL ALIGNMENT Specifications & Procedures

Vehicle height:

Fig. 96: Identifying Vehicle Height Specifications Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE: Before inspecting the wheel alignment, adjust the vehicle height to the specified value.

If the vehicle height is not the specified value, try to adjust by pushing down on or lifting the body. 2. Install camber/caster/kingpin gauge or position vehicle on wheel alignment tester .

2002 Toyota Corolla LE

2002 WHEEL ALIGNMENT Specifications & Procedures

Fig. 97: Installing Camber/Caster/Kingpin Gauge Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Follow the specific instructions of the equipment manufacturer. 3. Inspect camber, caster and steering axis inclination . Camber:

2002 Toyota Corolla LE

2002 WHEEL ALIGNMENT Specifications & Procedures

Fig. 98: Identifying Camber Specifications Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Caster:

Fig. 99: Identifying Caster Specifications Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Steering axis inclination:

Fig. 100: Identifying Steering Inclination Specifications Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. If the caster and steering axis inclination are not within the specified values, after the camber has been correctly adjusted, recheck the suspension parts for damaged and/or worn out parts. 4. Adjust camber . NOTE: After the camber has been adjusted, inspect the toe-in.

a. Remove the front wheel. b. Remove the 2 nuts on the lower side of the shock absorber.

2002 Toyota Corolla LE

2002 WHEEL ALIGNMENT Specifications & Procedures

Fig. 101: Loosening Lower Shock Absorber Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Coat the threads of the nuts with engine oil. d. Temporarily install the 2 nuts. e. Adjust the camber by pushing or pulling the lower side of the shock absorber in the direction in which the camber adjustment is required.

2002 Toyota Corolla LE

2002 WHEEL ALIGNMENT Specifications & Procedures

Fig. 102: Moving Shock Absorber To Adjust Camber Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. f. Tighten the nuts. Torque: 274 N.m (2,800 kgf.cm, 203 ft.lbf) g. Install the front wheel. Torque: 103 N.m (1,050 kgf.cm, 76 ft.lbf)

2002 Toyota Corolla LE

2002 WHEEL ALIGNMENT Specifications & Procedures

h. Check the camber. NOTE:

Try to adjust the camber to the center of the specified value. Adjusting value for the set bolts is 6' - 30' (0.1 - 0.5). If the camber i within the specified value, using the table in Fig. 103 , estimate how additional camber adjustment will be required, and select the cambe adjusting bolt.

Fig. 103: Displaying Camber Adjustment Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. i. Do steps through g again. Between steps a and b , replace 1 or 2 selected bolts. NOTE: 5. Inspect toe-in . When replacing the 2 bolts, replace 1 bolt for each time.

2002 Toyota Corolla LE

2002 WHEEL ALIGNMENT Specifications & Procedures

Fig. 104: Identifying Toe-In Measurements Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Toe-in (total):

Fig. 105: Identifying Toe-In Specifications Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. If the toe-in is not within the specified value, adjust it at the rack ends. 6. Adjust toe-in . a. Remove the rack boot set clips. b. Loosen the tie rod end lock nuts.

2002 Toyota Corolla LE

2002 WHEEL ALIGNMENT Specifications & Procedures

Fig. 106: Adjusting Tie Rod Ends Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. c. Turn the right and left rack ends by an equal amount to adjust the toe-in. NOTE: Try to adjust the toe-in to the center of the specified value.

d. Make sure that the lengths of the right and left rack ends are the same. Rack end length difference: 1.0 mm (0.039 in.) or less

2002 Toyota Corolla LE

2002 WHEEL ALIGNMENT Specifications & Procedures

Fig. 107: Checking For Equal Rack End Lengths Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. e. Torque the tie rod end lock nuts. Torque: 56 N.m (570 kgf.cm, 41 ft.lbf) f. Place the boots on the seats and install the clips. NOTE: Make sure that the boots are not twisted.

7. Inspect wheel angle . Turn the steering wheel fully, and measure the turning angle.

2002 Toyota Corolla LE

2002 WHEEL ALIGNMENT Specifications & Procedures

Fig. 108: Identifying Wheel Turning Angles Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Wheel turning angle: See Fig. 109 .

Fig. 109: Identifying Wheel Turning Specifications Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. If the right and left inside wheel angles differ from the specified value, check the right and left rack end lengths.
Rear Wheel Alignment

2002 Toyota Corolla LE

2002 WHEEL ALIGNMENT Specifications & Procedures

1. Measure vehicle height (see MEASURE VEHICLE HEIGHT ) . 2. Install camber/caster/kingpin gauge or position vehicle on wheel alignment tester . Follow the specific instructions of the equipment manufacturer. 3. Inspect camber . Camber:

Fig. 110: Identifying Camber Specifications Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. If the measured value is not within the specified value, inspect the suspension parts for damage and/or wear and replace them if necessary because camber is not adjustable. 4. Inspect toe-in .

2002 Toyota Corolla LE

2002 WHEEL ALIGNMENT Specifications & Procedures

Fig. 111: Identifying Toe-In Measurements Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Toe-in (total):

Fig. 112: Identifying Toe-In Specifications Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. If the toe-in is not within the specified value, adjust it at the No. 2 lower suspension arm. 5. Adjust toe-in . a. Measure the lengths of the right and left No. 2 lower suspension arms.

Fig. 113: Measuring Lower Suspension Arm Lengths Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. No. 2 lower suspension arm length difference:

2002 Toyota Corolla LE

2002 WHEEL ALIGNMENT Specifications & Procedures

1 mm (0.04 in.) or less If the right-left difference is greater than the specified value, adjust the length. b. Loosen the lock nuts. c. Turn the right and left adjusting tube by an equal amount to adjust toe-in.

Fig. 114: Adjusting Toe-In Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE:

Try to adjust the toe-in to the center value. One turn of the each adjusting tube will adjust the toe-in by about 54' (0.9, 9.0 mm, 0.354 in.).

d. Torque the lock nuts. Torque: 56 N.m (570 kgf.cm, 41 ft.lbf) SPECIFICATIONS

2002 Toyota Corolla LE

2002 WHEEL ALIGNMENT Specifications & Procedures

Fig. 115: Wheel Alignment Specifications (Corolla) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2001-02 AUTOMATIC TRANSMISSIONS A-131L Diagnosis

2001-02 AUTOMATIC TRANSMISSIONS A-131L Diagnosis

APPLICATION
WARNING: Vehicle is equipped with Supplemental Inflatable Restraint (SIR) system. When servicing vehicle, use care to avoid accidental air bag deployment. SIR system-related components are located in various locations throughout interior and exterior of vehicle, depending on application. Do not use electrical test equipment on or near these circuits. If necessary, deactivate SIR system before servicing components. See AIR BAG DEACTIVATION PROCEDURES article in GENERAL INFORMATION. TRANSAXLE APPLICATION Application Corolla

Transaxle Model A-131L

IDENTIFICATION
The vehicle identification number is used for correct identification of components. The vehicle identification number is located on the upper left corner of the instrument panel, under the windshield. The certification label is located on the left front door pillar. See Fig. 1 .

2001-02 AUTOMATIC TRANSMISSIONS A-131L Diagnosis

Fig. 1: Locating Vehicle Identification Number Plates Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

DESCRIPTION & OPERATION

INTRODUCTION The A-131L transaxle has 3 forward speeds and reverse. Transaxle is not controlled by an Electronic Control Module (ECM) and does not have a self-diagnostic system which will store a Diagnostic Trouble Code (DTC). Only component tests are available. For additional information on transaxle operation, see appropriate OVERHAUL article. SHIFT INTERLOCK SYSTEM The vehicle is equipped with a shift interlock and key lock system. The shift interlock system prevents the gearshift lever from being moved from the PARK position unless brake pedal is depressed. In case of a malfunction, the gearshift lever can be released by depressing the shift interlock override button located in the gearshift indicator plate. The key lock system prevents ignition key from being moved from ACC to LOCK position on ignition switch unless the gearshift lever is in the PARK position. For more information on shift interlock and key lock system, see appropriate SHIFT INTERLOCK SYSTEMS article. TORQUE CONVERTER CLUTCH

2001-02 AUTOMATIC TRANSMISSIONS A-131L Diagnosis

The torque converter clutch "locks up" in 3rd gear to provide a 1-to-1 ratio for increased efficiency. It does not operate in 1st or 2nd gears.

COMPONENT LOCATIONS
COMPONENT LOCATIONS Component Park/Neutral Position Switch Vehicle Speed Sensor Location On Rear Of Transaxle On Top Of Transaxle

For view of park/neutral position switch and vehicle speed sensor, see Fig. 2 and Fig. 3 .

Fig. 2: Locating Park/Neutral Position Switch Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2001-02 AUTOMATIC TRANSMISSIONS A-131L Diagnosis

Fig. 3: Location & View Of Vehicle Speed Sensor & Wiring Harness Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

TROUBLE SHOOTING
NOTE: Any diagnosis should begin with confirming the customer's complaint. If possible, road test vehicle first, and note transmission performance for future reference during diagnosis.

2001-02 AUTOMATIC TRANSMISSIONS A-131L Diagnosis

PRELIMINARY INSPECTION Automatic transaxle driveability concerns can be caused by either engine or transaxle. Isolate malfunction to engine or transaxle before proceeding with trouble shooting. Prior to trouble shooting, check and adjust throttle cable, shift linkage, park/neutral position switch and idle speed RPM as necessary. Ensure fluid level is correct. Check tires for correct inflation. SYMPTOM DIAGNOSIS
Delayed Upshifts, Or Downshifts From 3-2 Then Shifts Back To 3rd

Throttle cable out of adjustment, faulty valve body assembly or governor assembly.
Downshift Occurs Too Soon Or Too Late While Coasting

Throttle cable out of adjustment, faulty valve body assembly, transaxle assembly or governor assembly.
Drag, Binding Or Tie-Up On Upshifts

Shift cable out of adjustment, faulty valve body assembly or transaxle assembly.
Fluid Discolored Or Smells Burnt

Contaminated fluid, faulty torque converter or transaxle assembly.

Harsh Downshift

Throttle cable out of adjustment, throttle modulator valve or primary regulator valve stuck.
Harsh Engagement Into Any Forward Gear Position

Throttle cable out of adjustment, faulty valve body assembly, primary regulator valve or accumulators. See CLUTCH & BRAKE APPLICATIONS .
No Engine Braking In "2" Or "L" Position

1st and reverse brake or 2nd coast brake.

No Forward Gears

Faulty governor valve, forward clutch, No. 2 one-way clutch, 1st and reverse brake, 2nd coast brake, No. 1 one-way clutch or direct clutch.
No Lock-Up

Lock-up relay valve, lock-up signal valve or torque converter stuck or leaking.
No Movement In Any Gear Position

Shift cable out of adjustment, faulty valve body assembly, primary regulator valve, parking lock pawl, torque converter or front/rear planetary gear. Broken converter drive plate or blocked oil pump intake

2001-02 AUTOMATIC TRANSMISSIONS A-131L Diagnosis

screen.
No Kickdown

Faulty 1-2 or 2-3 shift valve.

No Reverse

Faulty 2nd coast brake, front or rear planetary gear, 1-2 shift valve, 2-3 shift valve, direct clutch or 1st and reverse brake.
Poor Acceleration

Faulty torque converter.

Selector Lever Position Incorrect

Shift cable out of adjustment, faulty manual valve and/or lever.

Slips On Upshift, Or Slips Or Shudders On Acceleration

Shift cable or throttle cable out of adjustment, faulty valve body assembly or clutch assemblies. See CLUTCH & BRAKE APPLICATIONS .
Vehicle Does Not Hold In "P" Position

Shift cable out of adjustment, faulty parking lock pawl cam and spring. CLUTCH & BRAKE APPLICATIONS CLUTCH & BRAKE APPLICATIONS Selector Lever Position "D" (Drive) 1st Gear 2nd Gear 3rd Gear "2" (Second) 1st Gear 2nd Gear

Elements In Use Forward Clutch & No. 2 OneWay Clutch Forward Clutch, No. 1 OneWay Clutch & 2nd Brake Forward Clutch, Direct Clutch & 2nd Brake Forward Clutch & No. 2 OneWay Clutch Forward Clutch, No. 1 OneWay Clutch, 2nd Brake & 2nd Coast Brake Band Forward Clutch, No. 2 OneWay Clutch & 1st & Reverse Brake

"L" (Low) 1st Gear

2001-02 AUTOMATIC TRANSMISSIONS A-131L Diagnosis

2nd Gear (1) "R" (Reverse) "N" Or "P"

(1) Downshift in "L" position, 2nd gear only. No upshift.

Forward Clutch, No. 1 OneWay Clutch, 2nd Brake & 2nd Coast Brake Band Direct Clutch & 1st & Reverse Brake All Clutches & Brakes Released Or Ineffective

PERFORMANCE TESTS
ROAD TEST NOTE: Perform test with fluid at normal operating temperature of 122-176F (50-80 C).

"D" Position Test

1. Shift vehicle into Drive. While driving vehicle, hold accelerator constantly at full throttle position. See SHIFT SPEED SPECIFICATIONS . Check 1-2 and 2-3 upshift points: If 1-2 upshift does not occur, 1-2 shift valve is stuck or governor valve is defective. If 2-3 upshift does not occur, 2-3 shift valve is stuck. If all shift points are incorrect, throttle cable is out of adjustment or throttle valve, 1-2 or 2-3 shift valves are defective. 2. Repeat procedure and check shock and slip during 1-2 and 2-3 upshifts. Excessive shock can be caused by excessive line pressure, defective accumulator or defective check ball. 3. While driving vehicle in "D" position, check for abnormal noise or vibration. Abnormal noise or vibration may be due to an unbalanced axle shaft, differential, tires or torque converter. 4. While driving vehicle in 3rd gear, confirm correct kickdown speed limits for 3-2 and 2-1 shift points. Check for abnormal shock or slip at kickdown. If kickdown speed limit is incorrect, throttle cable is out of adjustment or throttle valve, 1-2 or 2-3 shift valves are defective. 5. Drive vehicle in "D" position at 37 MPH. Release accelerator pedal and shift into "L" position. Confirm correct downshift speed limits for 2-1 shift point.
Lock-Up Mechanism

Drive vehicle in "D" position with lock-up on and hold vehicle at specified speed. See LOCK-UP SPEED SPECIFICATIONS . Lightly depress accelerator pedal. Ensure engine RPM does not change abruptly. Large increase in engine RPM indicates lock-up function is faulty.
"2" Position Test

While driving vehicle in "2" position, release accelerator pedal and check engine braking effect. If no engine braking occurs, 2nd coast brake is defective. Check for abnormal noise during acceleration and deceleration. Check for shock during upshift and downshift.
"L" Position Test

2001-02 AUTOMATIC TRANSMISSIONS A-131L Diagnosis

While driving vehicle in "L" position, ensure upshift to 2nd gear does not occur. Release accelerator pedal. If engine braking does not occur, 1st and reverse brake is defective.
"R" Position Test

Shift vehicle to "R" position. Accelerate vehicle from a stop to full throttle. Ensure slipping does not occur.
"P" Position Test

Stop vehicle on slight incline. Shift vehicle to "P" position. Release parking brake. Ensure parking lock pawl holds vehicle. SHIFT SPEED SPECIFICATIONS Application "D" Position (1) 1-2 2-3 3-2 2-1 "L" Position (2) 2-1 (1) Wide open throttle.
(2) Fully closed throttle.

MPH 31-42 60-72 58-68 22-29 26-34

LOCK-UP SPEED SPECIFICATIONS (1) Application "D" position (2) Lock-Up On (1) Lock-Up Off (1) (1) Fully closed throttle.
(2) There is no lock-up in "L" or "2" position.

MPH 41-48 39-46

TORQUE CONVERTER
Stall Speed Test

1. Operate engine and transaxle at normal operating temperature. Connect scan tool to vehicle and monitor engine RPM. Apply parking brake and block front and rear wheels. CAUTION: Do not maintain stall speed RPM for more than 5 seconds.

2. Start engine, apply brakes and place selector lever in "D" position. Depress accelerator to full throttle and note maximum RPM obtained. Repeat test in "R" position. For stall speeds, see STALL SPEED

2001-02 AUTOMATIC TRANSMISSIONS A-131L Diagnosis

SPECIFICATIONS table. STALL SPEED SPECIFICATIONS Application Corolla

Stall Speed Test Results

RPM 2350-2650

1. If stall speed is same in both "D" and "R" position, but less than specified, check for insufficient engine output or defective stator one-way clutch. NOTE: If stall speed is 601 RPM or more, or less than specification, torque converter may be faulty.

2. If stall speed is high in "D" position, check for low line pressure, forward clutch slipping or defective No. 2 one-way clutch. 3. If stall speed is high in "R" position, check for low line pressure or slipping direct clutch or 1st and reverse brake. 4. If stall speed is high in both positions, check for low line pressure or improper fluid level. HYDRAULIC PRESSURE TESTS CAUTION: Perform tests with fluid at normal operating temperature of 122-176F (50-80C).
Line Pressure Test

1. Remove appropriate transaxle case plug and connect pressure gauge. See Fig. 4 . Block all wheels. Apply parking brake. Start engine and shift into "D" position. Ensure idle speed is set to specification. 2. Apply service brakes and depress accelerator. Note pressure readings at idle and stall speeds. Repeat test in "R" position. Compare pressure readings to those listed in LINE PRESSURE SPECIFICATIONS table. 3. If pressure is less than specified, check throttle cable adjustment. Adjust as necessary. See appropriate AUTOMATIC article in TRANSMISSION SERVICING for adjustment procedure. Repeat pressure test procedure if throttle cable adjustment was necessary.
Line Pressure Test Results

1. If line pressure is high in both positions, check for misadjusted throttle cable, defective throttle valve or regulator valve. 2. If line pressure is low in both positions, check for misadjusted throttle cable, defective oil pump, throttle valve or regulator valve. 3. If line pressure is low in "D" position only, check for leaking pressure in "D" position circuit or defective forward clutch. 4. If line pressure is low in "R" position only, check for leaking pressure in "R" position circuit, defective 1st and reverse brake or direct clutch.

2001-02 AUTOMATIC TRANSMISSIONS A-131L Diagnosis

Fig. 4: Locating Hydraulic Pressure Test Ports Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. LINE PRESSURE SPECIFICATIONS Application "D" Position Idle Speed Stall Speed "R" Position Idle Speed Stall Speed
Governor Pressure Test

psi (kg/cm2 ) 54-61 (3.8-4.3) 131-152 (9.2-10.7) 80-102 (5.6-7.2) 205-239 (14.4-16.8)

NOTE:

Road test vehicle or use chassis dynamometer to check governor pressures exceeding minimum vehicle speed specification.

1. Apply parking brake. Raise and support front of vehicle with safety stands. Remove appropriate transaxle case plug and connect pressure gauge. See Fig. 4 . 2. Start engine and shift to "D" position. Note governor pressure at specified speeds and engine RPM. See GOVERNOR PRESSURE SPECIFICATIONS . Incorrect governor pressure may be caused by incorrect line pressure, leakage at governor pressure circuit or defective governor valve. GOVERNOR PRESSURE SPECIFICATIONS Vehicle Speed (MPH) 19 37 56

psi (kg/cm2 ) 11-12 (.7-.8) 29-30 (2.0-2.1) 47-50 (3.3-3.5)

2001-02 AUTOMATIC TRANSMISSIONS A-131L Diagnosis

TIME LAG TEST NOTE: Perform test with fluid at normal operating temperature of 122-176F (50-80 C). Wait one minute between tests. Record 3 measurements and use average value.

1. If selector lever is actuated with engine idling, a time lag will be noted before shock can be felt. Apply parking brake and block front and rear wheels. Start engine and check idle speed. Idle speed should be 650-750 RPM. Idle speed is controlled by computer and is not adjustable. 2. Move selector lever from "N" to "D" position. Measure time required for shock to be felt. Time lag must be less than 1.2 seconds. Repeat procedure, shifting from "N" to "R" position. Time lag must be less than 1.5 seconds.
Time Lag Test Results

1. If time lag from "N" to "D" position is excessive, check for low line pressure or defective forward clutch. 2. If time lag from "N" to "R" position is excessive, check for low line pressure, defective direct clutch or 1st and reverse brake.

COMPONENT TESTS
PARK/NEUTRAL POSITION SWITCH Disconnect harness connector at Park/Neutral Position (PNP) switch. Switch is located on side of transaxle, under the shift shaft bracket. See Fig. 2 . Using ohmmeter, check for continuity between specified terminals in accordance with the gearshift lever position. See Fig. 5 . Replace PNP switch if defective. See REMOVAL & INSTALLATION in appropriate AUTOMATIC article in TRANSMISSION SERVICING.

2001-02 AUTOMATIC TRANSMISSIONS A-131L Diagnosis

Fig. 5: Testing Park/Neutral Position Switch Continuity Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

REMOVAL & INSTALLATION

NOTE: For removal and installation procedures of external components, see REMOVAL & INSTALLATION in appropriate AUTOMATIC article in TRANSMISSION SERVICING.

CONNECTOR IDENTIFICATION

2001-02 AUTOMATIC TRANSMISSIONS A-131L Diagnosis

Fig. 6: Identifying Park/Neutral Position Switch Connector Terminals Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2001-02 AUTOMATIC TRANSMISSIONS A-131L Diagnosis

Fig. 7: Identifying Vehicle Speed Sensor Connector Terminals Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

WIRING DIAGRAMS
NOTE: For VSS circuit identification, see appropriate INSTRUMENT PANELS article in ACCESSORIES & EQUIPMENT. For PNP switch circuit identification, see appropriate SHIFT INTERLOCK SYSTEMS article.

2001-02 AUTOMATIC TRANSMISSIONS A-245E Diagnosis

2001-02 AUTOMATIC TRANSMISSIONS A-245E Diagnosis

APPLICATION
WARNING: Vehicle is equipped with Supplemental Inflatable Restraint (SIR) system. When servicing vehicle, use care to avoid accidental air bag deployment. SIR system-related components are located in various locations throughout interior and exterior of vehicle, depending on application. Do not use electrical test equipment on or near these circuits. If necessary, deactivate SIR system before servicing components. See AIR BAG DEACTIVATION PROCEDURES article in GENERAL INFORMATION. TRANSAXLE APPLICATION Application Corolla 1.8L

Transaxle Model A-245E

IDENTIFICATION
Vehicle Identification Number (VIN) is used for correct identification of component parts and assemblies. VIN locations are at top left corner of instrument panel and on driver's door post. See Fig. 1 .

2001-02 AUTOMATIC TRANSMISSIONS A-245E Diagnosis

Fig. 1: Locating Vehicle Identification Number Plates Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

DESCRIPTION & OPERATION

INTRODUCTION Transaxle has 4 forward speeds and reverse. Transaxle assembly consists of a lock-up torque converter clutch, oil pump, valve body assembly, forward clutch, direct clutch, underdrive clutch, differential, 3 planetary gear sets and 3 one-way clutches. See Fig. 2 . The A-245E series transaxle shifting and torque converter clutch lock-up are controlled by the Engine Control Module (ECM).

2001-02 AUTOMATIC TRANSMISSIONS A-245E Diagnosis

Fig. 2: Identifying Transaxle Internal Components Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. The A-245E series transaxle is electronically controlled. Transaxle shifting and torque converter lock-up are controlled by the Engine Control Module (ECM). ECM receives information from various input devices and uses this information to control No. 1 and No. 2

2001-02 AUTOMATIC TRANSMISSIONS A-245E Diagnosis

solenoids for transaxle shifting and lock-up solenoid (also known as SL solenoid) for torque converter lockup. An Overdrive (O/D) switch is mounted on shift lever. See Fig. 3 . When O/D switch is depressed to ON position, transaxle will shift into 4th gear when shift lever is in "D" position, and O/D OFF light on instrument panel will go off. When O/D switch is released to OFF position, transaxle will shift into 3rd gear, and O/D OFF light will illuminate. Transaxle is equipped with a shift lock and key lock system. Shift lock system prevents shift lever from being moved from Park unless brake pedal is depressed. In case of a malfunction, shift lever can be released by depressing shift lock override button located near shift lever. Key lock system prevents ignition key from being moved from ACC to LOCK position on ignition switch unless shift lever is in Park. For more information on shift lock and key lock system, see appropriate SHIFT INTERLOCK SYSTEMS article. ELECTRONIC CONTROL MODULE ECM receives information from various input devices and uses this information to control No. 1, No. 2 and SL solenoids. ECM contains a self-diagnostic system, which will store a Diagnostic Trouble Code (DTC) if failure or problem exists in electronic control system. DTC can be retrieved to determine transaxle problem area. ECM is located near front of center console. See Fig. 3 .

2001-02 AUTOMATIC TRANSMISSIONS A-245E Diagnosis

Fig. 3: Identifying Input & Output Devices Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. ELECTRONIC CONTROL MODULE INPUT DEVICES

2001-02 AUTOMATIC TRANSMISSIONS A-245E Diagnosis

Brakelight Switch

Brakelight switch delivers input signal to ECM, indicating vehicle braking. Brakelight switch is located on brake pedal support.
Cruise Control Electronic Control Unit

Cruise control Electronic Control Unit (ECU) delivers an input signal to control overdrive operation in accordance with vehicle speed when cruise control is operating. When in overdrive with cruise control on, if vehicle speed drops 3 MPH less than set speed, overdrive is released to prevent reduction in vehicle speed. Once vehicle speed is more than set speed, overdrive is resumed. Cruise control ECU is located behind instrument panel on passenger side of vehicle.
Engine Coolant Temperature Sensor

Engine Coolant Temperature (ECT) sensor delivers input signal to ECM, indicating engine coolant temperature. Coolant temperature sensor is located in thermostat housing.
O/D Switch

O/D switch provides an input signal to ECM to indicate when overdrive is selected by vehicle operator. When O/D switch is depressed to ON position, transaxle will shift into 4th gear when shift lever is in "D" position, and O/D OFF light on instrument panel will go off. See Fig. 3 . When O/D switch is released to OFF position, transaxle will shift into 3rd gear, and O/D OFF light will come on. O/D switch is mounted on shift lever.
Park/Neutral Position Switch

Park/Neutral position switch delivers an input signal to ECM to indicate shift lever position. Park/Neutral position switch is located on side of transaxle. See Fig. 3 .
Throttle Position Sensor

Throttle Position (TP) sensor delivers an input signal to ECM indicating throttle position. TP sensor is located on side of throttle body.
Vehicle Speed Sensor

Vehicle Speed Sensor (VSS) signal is delivered to ECM by speed sensors. Speed sensors are located on transaxle and in combination meter on some models. ECM OUTPUT DEVICES
No. 1 & No. 2 Solenoids

ECM controls transaxle shifting by delivering an output signal to operate proper solenoid. Solenoids are operated in accordance with shift lever position. If a solenoid malfunctions, ECM places transaxle in designated gear. See Fig. 4 . Solenoids are located on transaxle valve body. See Fig. 3 . NOTE: In some gears, ECM provides a fail-safe system which places transaxle in a designated gear depending on which solenoid fails. In some gears, fail-safe

2001-02 AUTOMATIC TRANSMISSIONS A-245E Diagnosis

system will not be activated and transaxle will be placed in specified gear. See Fig. 4 .

Fig. 4: Testing No. 1 & No. 2 Solenoid Operation Courtesy of TOYOTA MOTOR SALES, U.S.A., INC..
SL Solenoid

ECM controls torque converter lock-up by delivering an output signal to SL solenoid. SL solenoid is activated when shift lever is in "D" position and vehicle is at specified speed. SL solenoid is located on transaxle valve body. See Fig. 3 . SHIFT INTERLOCK SYSTEM The vehicle is equipped with a shift interlock and key lock system. The shift interlock system prevents the gearshift lever from being moved from the PARK position unless brake pedal is depressed. In case of a malfunction, the gearshift lever can be released by depressing the shift interlock override button located near the gearshift lever. The key lock system prevents ignition key from being moved from ACC to LOCK position on ignition switch unless the gearshift lever is in the PARK position. For more information on shift interlock and key lock system, see appropriate SHIFT INTERLOCK SYSTEMS article.

COMPONENT LOCATIONS
COMPONENT LOCATIONS Component Data Link Connector ECM MIL O/D Main Switch Stop Light Switch Vehicle Speed Sensor Location Under Left Side Of Instrument Panel Behind Forward Section Of Console, Below Instrument Panel In Instrument Cluster On Gearshift Lever On Brake Pedal Bracket On Transaxle

TROUBLE SHOOTING

2001-02 AUTOMATIC TRANSMISSIONS A-245E Diagnosis

NOTE:

Any diagnosis should begin with confirming the customer's complaint. If possible, road test vehicle first, and note transmission performance for future reference during diagnosis. When troubleshooting transaxle, perform PRELIMINARY INSPECTION first, then check for stored DTCs and repair as necessary. If no DTCs exist, perform manual shift test to determine if transaxle problem area is an electrically or mechanically related concern. See .MANUAL SHIFT TEST under TROUBLE SHOOTING.

PRELIMINARY INSPECTION Prior to diagnosing the transmission electronic control system, ensure throttle and shift cables are properly adjusted and fluid level is correct. Ensure engine starts with gearshift lever in Park and Neutral to ensure proper adjustment of park/neutral position switch. Ensure all system-related fuses are okay. Check system wire harnesses for proper routing. Verify all harness and component connections are clean and tight. Repair as necessary. If area of fault cannot be located or repaired during preliminary inspection, begin diagnosis of self-diagnostic system. See RETRIEVING DIAGNOSTIC TROUBLE CODES under SELFDIAGNOSTIC SYSTEM. SYMPTOM DIAGNOSIS
Fluid Discolored Or Smells Burnt

Fluid contaminated. Torque converter faulty. Transaxle faulty.

Harsh Engagement Neutral To Drive

Check forward clutch accumulator, throttle valve and forward clutch.

Harsh Engagement Neutral To Reverse

Check direct clutch accumulator, direct clutch, throttle valve and, 1st and reverse brake.
No Engine Braking In Low

Check low coast modulator valve and, 1st and reverse brake.
No Engine Braking In 2nd

Check 2nd coast modulator valve and 2nd coast brake.

No O/D-3 Downshift

Check No. 1 and No. 2 shift solenoid valve, VSS circuit, O/D cancel signal circuit, ECM/PCM circuit and 34 shift valve.
No Torque Converter Lock-Up

Check shift solenoid valve SL circuit, TP sensor circuit, VSS circuit, O/D cancel circuit, brakelight circuit, ECT sensor circuit, ECM/PCM circuit, lock-up relay valve and torque converter clutch.

2001-02 AUTOMATIC TRANSMISSIONS A-245E Diagnosis

No 1-2 &/Or 2-3 Upshift

Check Throttle Position (TP) sensor circuit, No. 1 and No. 2 shift solenoid circuit, Vehicle Speed Sensor (VSS) circuit, ECM/PCM, 1-2 shift valve, 2-3 shift valve, 2nd brake, direct clutch and No. 1 one-way clutch.
No 3-O/D Upshift

Check O/D switch and O/D OFF indicator switch circuit, O/D cancel signal circuit, No. 1 and No. 2 shift solenoid circuit, VSS circuit, Engine Coolant Temperature (ECT) sensor circuit, ECM/PCM, 3-4 shift valve and U/D brake.
No 3-2 &/Or 2-1 Downshift

Check No. 1 and No. 2 shift solenoid valve, VSS circuit, TP sensor circuit, ECM/PCM circuit, 2-3 shift valve, 1-2 shift valve and 2nd coast brake.
Shift Speeds Too High Or Too Low

Check TP sensor circuit, VSS circuit, shift solenoid valve SL circuit, O/D cancel signal circuit, pattern select switch circuit and ECM/PCM.
Torque Converter Lock-Up Will Not Release

Check shift solenoid valve SL circuit, TP sensor circuit, IDL switch circuit, brakelight circuit, ECM/PCM circuit, lock-up relay valve and torque converter clutch.
Vehicle Does Not Move In Any Forward Gear

Check forward clutch, No. 2 one-way clutch, 1st and reverse brake, 2nd coast brake, 2nd brake and direct clutch.
Vehicle Does Not Move In Any Forward Gear Or Reverse

Check manual valve, parking lock pawl, primary regulator valve, underdrive (U/D) one-way clutch, U/D clutch, U/D brake, front planetary gear, rear planetary gear, U/D planetary gear and torque converter.
Vehicle Does Not Move In Reverse Gear

Check 1-2 shift valve, 2-3 shift valve, 2nd coast brake, front planetary gear, rear planetary gear, direct clutch, U/D clutch and 1st and reverse brake. CLUTCH & BRAKE APPLICATIONS CLUTCH & BRAKE APPLICATIONS Selector Lever Position "D" (Drive) 1st Gear

Elements In Use Forward Clutch, No. 2 One-Way Clutch, Underdrive One-Way Clutch & Underdrive Brake Forward Clutch, No. 1 One-Way Clutch,

2nd Gear

2001-02 AUTOMATIC TRANSMISSIONS A-245E Diagnosis

3rd Gear

O/D "2" (2nd) 1st Gear

2nd Brake, Underdrive Brake & Underdrive One-Way Clutch Direct Clutch, Forward Clutch, 2nd Brake, Underdrive Brake & Underdrive One-Way Clutch Direct Clutch, Forward Clutch, 2nd Brake & Underdrive Clutch Forward Clutch, No. 2 One-Way Clutch, Underdrive One-Way Clutch & Underdrive Brake Forward Clutch, 2nd Brake, No. 1 OneWay Clutch, Underdrive Brake, Underdrive One-Way Clutch & 2nd Coast Brake Direct Clutch, Forward Clutch, 2nd Brake, Underdrive Brake & Underdrive One-Way Clutch Forward Clutch, Underdrive Brake, No. 2 One-Way Clutch, Underdrive OneWay Clutch, & 1st & Reverse Brake Forward Clutch, 2nd Coast Brake, 2nd Brake, No. 1 One-Way Clutch, Underdrive One-Way Clutch & Underdrive Brake Direct Clutch, Underdrive Brake, & 1st & Reverse Brake Underdrive Brake Underdrive Brake

2nd Gear

3rd Gear (1) "L" (Low) 1st Gear

2nd Gear (2)

"R" (Reverse) "N" (Neutral) "P" (Park) (1) Downshift only in 3rd gear for "2" position.

(2) Downshift only in 2nd gear for "L" position. Upshift does not occur.

PERFORMANCE TESTS
ROAD TEST NOTE:
"D" Position

Perform test at normal operating fluid temperature of 122-176F (50-80C).

1. Shift transaxle into Drive. Hold accelerator pedal constant at full throttle. Check 1-2, 2-3, and 3-4 upshift and lock-up points. See SHIFT SPEED SPECIFICATIONS and LOCK-UP SPEED SPECIFICATIONS . NOTE: There is no overdrive lock-up when coolant temperature is below 140F (60C) or when vehicle speed is 6 MPH less than the set cruise control

2001-02 AUTOMATIC TRANSMISSIONS A-245E Diagnosis

speed. There is no lock-up when brake pedal is depressed.

If no 1-2 upshift occurs, check lower valve body control valves or shift solenoid. If no 2-3 upshift occurs, check lower valve body control valves or shift solenoid. If no 3-4 upshift occurs, check 3-4 shift valve or shift solenoid. If all shift points are incorrect, check upper valve body, lower valve body control valves and 3-4 shift valve. If all lock-up points are incorrect, check lock-up relay valve or shift solenoid.

2. Use procedure outlined in step 1 to check for shock and slip between 1-2, 2-3 and 3-4 upshifts. If shock is harsh, line pressure may be too high. Check accumulator or check ball. 3. Drive vehicle Drive during lock-up or Overdrive. Check for abnormal noise and vibration. NOTE: Check for cause of abnormal noise and vibration must be made with extreme care as problem could be due to an unbalanced drive axle, differential, tire, torque converter, etc.

4. While driving in Drive, confirm correct kickdown vehicle speed limits for 2-1, 3-2, 4-3 shift points. Check for abnormal shock and slip at kickdown. 5. Check lock-up function. Drive vehicle in Overdrive ("D" position) with lock-up on. Hold vehicle speed steady at 37 MPH. Lightly depress accelerator pedal. Ensure engine RPM does not change abruptly. Large increase in engine RPM indicates lock-up function is faulty.
"2" Position

1. Shift transaxle to manual 2nd gear. Drive vehicle with accelerator pedal held constantly at full throttle. Ensure 1-2 upshift points take place and are operating properly. NOTE: In "2" position, there will be no lock-up in 2nd gear.

2. While driving in manual 2nd gear, release accelerator pedal and check engine braking effect. If there is no engine braking effect, 2nd brake is defective. Check for abnormal noise and shock at acceleration and deceleration.
"L" Position

While driving in Low, ensure there is no upshift to 2nd gear. While driving in Low, release accelerator pedal. If there is no engine braking effect, 1st/reverse brake is defective. Check for abnormal noise during acceleration and deceleration.
"R" Position

Shift transaxle into Reverse. Accelerate in Reverse from a stop at full throttle. Ensure slipping does not occur.

2001-02 AUTOMATIC TRANSMISSIONS A-245E Diagnosis

"P" Position

Stop vehicle on grade of more than 5 percent. Shift transaxle into Park. Release parking brake. Ensure parking pawl holds vehicle. SHIFT SPEED SPECIFICATIONS SHIFT SPEED SPECIFICATIONS Application "D" Position 1st-2nd (1) 2nd-3rd (1) 3rd-4th (1) 4th-3rd (1) 3rd-2nd (1) 3rd-4th (2) 4th-3rd(2) 2nd-1st (1) "2" Position 1st-2nd (1) 3rd-2nd (1) 2nd-1st (1) "L" Position 2nd-1st (1) (1) Wide open throttle.
(2) Fully closed throttle.

MPH 36-42 67-74 92-101 89-98 60-65 22-26 11-14 27-31 34-39 56-62 25-29 27-31

LOCK-UP SPEED SPECIFICATIONS LOCK-UP SPEEDS Application "D" Position Lock-Up On in 3rd (1) Lock-Up Off in 3rd (1) Lock-Up On in O/D (1) Lock-Up Off in O/D (1) (1) Throttle valve opening at 5 percent. TORQUE CONVERTER CAUTION: Perform test at normal operating fluid temperature of 122-176F (50-80

MPH 39-44 34-39 39-43 34-39

2001-02 AUTOMATIC TRANSMISSIONS A-245E Diagnosis

C). DO NOT continue test for more than 10 seconds.

Stall Speed Test

1. Testing is done to check overall performance of transaxle and engine by measuring maximum engine speeds in Drive and Reverse. 2. Block front and rear wheels. Connect scan tool to Data Link Connector (DLC3) to monitor engine RPM. Apply parking and service brakes. Start engine. Shift transaxle into Drive. Fully depress accelerator pedal. Release pedal within 10 seconds. 3. Record highest engine RPM. Compare reading obtained to specification. Specified stall speed is 23502650 RPM. Repeat test in Reverse. 4. If stall speed is same for both positions, but lower than specified RPM, engine output may be insufficient or stator one-way clutch is not operating properly. NOTE: If stall speed RPM is more than 600 RPM less than specification, torque converter may be faulty.

5. If stall speed in Drive is higher than specification, forward clutch may be slipping, No. 2 one-way clutch may not be operating properly, or line pressure is too low. 6. If stall speed in Reverse is higher than specification, reverse clutch may be slipping, 1st/reverse brake may be slipping or line pressure is too low. 7. If stall speed in Reverse and Drive is higher than specification, line pressure is too low, fluid level is incorrect or No. 2 one-way clutch is not operating properly. HYDRAULIC PRESSURE TESTS CAUTION: Perform test at normal operating fluid temperature of 122-176F (50-80 C). 1. Ensure transaxle fluid is at normal operating temperature. Raise and support vehicle. Remove transaxle case line pressure test plug. See Fig. 5 . Install hydraulic pressure gauge. Lower vehicle. 2. Fully apply parking brake. Block all wheels. Start engine and ensure idle speed is 650-750 RPM. Shift transaxle into Drive. Read and record line pressure at idle. Fully apply brakes. Depress accelerator pedal to floor. DO NOT apply full throttle for more than 10 seconds. 3. Measure highest line pressure. Compare reading obtained to specification. See LINE PRESSURE SPECIFICATIONS . Repeat test in Reverse. If pressures exceed specification in all ranges, regulator valve or shift solenoid SLT in upper valve body is defective. Ensure no TP sensor-related trouble codes are present. 4. If pressures in both positions are less than specified, oil pump, regulator valve or shift solenoid SLT is defective. Ensure no TP sensor-related trouble codes are present. 5. If pressure is less than specified in Drive only, forward clutch is defective or Drive circuit has a fluid leak. If pressure is less than specified in Reverse only, reverse clutch is defective, 1st/reverse brake is defective or Reverse circuit has a fluid leak.

2001-02 AUTOMATIC TRANSMISSIONS A-245E Diagnosis

Fig. 5: Locating Transaxle Line Pressure Test Port Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. LINE PRESSURE SPECIFICATIONS Engine RPM "D" Range - psi (kg/cm2 ) Idle Stall TIME LAG TEST CAUTION: Perform this test at normal operating fluid temperature of 122-176F (50-80C). Allow one minute between tests. Record 3 measurements and average results. 1. If selector lever is actuated with engine idling, a time lag will be noted before shock can be felt. This test is used for checking condition of No. 2 one-way clutch, forward clutch, reverse clutch and 1st/reverse brake. 2. Apply parking brake. Connect scan tool to Data Link Connector (DLC3) to monitor engine RPM. Start engine. Ensure idle speed is 650-750 RPM, with transaxle in Neutral and A/C off. Shift transaxle from Neutral into Drive. Use a stop watch to measure elapsed time from when gearshift lever is moved to when shock is felt. 3. Standard time lag is less than 0.7 second. Repeat test to measure time lag for Neutral-to-Reverse. Standard time lag is less than 1.2 seconds. 4. If Neutral-to-Drive time lag is longer than specified, line pressure is too low, forward clutch may be worn or No. 2 one-way clutch is not operating properly. 5. If Neutral-to-Reverse time lag is longer than specified, reverse clutch may be worn, 1st/reverse brake may be worn or line pressure is too low. 54-64 (3.8-4.5) 142-165 (10.0-11.6)

"R" Range - psi (kg/cm2 ) 87-104 (6.1-7.3) 201-249 (14.2-17.5)

2001-02 AUTOMATIC TRANSMISSIONS A-245E Diagnosis

MANUAL SHIFT TEST NOTE: Perform manual shift test if no DTCs are stored. Manual shift test determines if transaxle problem is electrically or mechanically related.

Ensure ignition is in OFF position. Disconnect 10-pin transaxle connector located above PNP switch on transaxle. Road test vehicle and ensure transaxle gear changes correspond with selector lever position. See GEAR APPLICATION table. If abnormality exists, a mechanical transaxle problem may exist. Turn ignition switch to OFF position. Reconnect transaxle connector. NOTE: Disconnecting transaxle connector may set DTC. Clear DTCs from ECM memory. See CLEARING DIAGNOSTIC TROUBLE CODES under SELFDIAGNOSTIC SYSTEM.

GEAR APPLICATION Selector Lever Position "D" "2" "L" "R" "P"

Gear Overdrive Overdrive 1st Reverse Park

SELF DIAGNOSTIC SYSTEM

NOTE: Before testing transaxle, ensure fluid level is correct and shift linkage is properly adjusted. Ensure engine starts with selector lever in Park and Neutral to ensure proper adjustment of park/neutral position switch.

RETRIEVING DIAGNOSTIC TROUBLE CODES NOTE: Before retrieving DTCs, ensure sufficient battery voltage exists for proper self-diagnostic system operation. Ensure proper operation of MIL. MIL will illuminate for all OBD-II DTCs that affect emissions. For additional engine performance or emission system-related DTCs not listed under DIAGNOSTIC TROUBLE CODE DEFINITIONS , see appropriate SELF-DIAGNOSTICS article in ENGINE PERFORMANCE.

Connect scan tool to Data Link Connector (DLC3). See Fig. 6 . DLC3 is located under left side of instrument panel. See Fig. 3 . Turn ignition on. Turn on scan tool. If using Toyota Scan Tool, ensure tool is in NORMAL MODE. CHECK MODE will erase all DTCs. Retrieve any DTCs stored in memory following scan tool instructions. See DIAGNOSTIC TROUBLE CODE DEFINITIONS . Record DTCs and any freeze-frame data. NOTE: Turning ignition switch to OFF position while in CHECK MODE, will erase all DTCs and freeze-frame data.

If using Toyota Scan Tool, CHECK MODE may be used to detect malfunctions. CHECK MODE has a higher sensing ability as compared to NORMAL MODE. With Toyota Scan Tool connected to DLC3, turn

2001-02 AUTOMATIC TRANSMISSIONS A-245E Diagnosis

ignition switch and scan tool ON. Switch Toyota Scan Tool from NORMAL MODE to CHECK MODE. Ensure MIL flashes. Start engine and simulate conditions of malfunction as described by customer. Ignition switch MUST be on at all times. Check DTCs and freeze-frame data.

Fig. 6: Connecting Scan Tool To Data Link Connector (DLC3) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.. DIAGNOSTIC TROUBLE CODE DEFINITIONS DIAGNOSTIC TROUBLE CODE DEFINITIONS DTC P0500 P0750 P0753 P0755 P0758 P0770 P0773
(1) Probable Cause

Vehicle Speed Sensor

(2) No. 1 Solenoid

No. 1 Solenoid Circuit Malfunction

(2) No. 2 Solenoid

No. 2 Solenoid Circuit Malfunction

(2) (3) Lock-Up Solenoid (3) Lock-Up Solenoid Circuit Malfunction

P1520 Brakelight Switch Signal P1780 Park/Neutral Position Switch Malfunction (1) Check listed component for probable cause. Check wiring and connections of specified component. (2) To diagnose this component, see SOLENOIDS under COMPONENT TESTS.

2001-02 AUTOMATIC TRANSMISSIONS A-245E Diagnosis

(3) Also known as SL solenoid.

CLEARING DIAGNOSTIC TROUBLE CODES Once repairs have been performed, DTCs must be cleared from ECM memory. DTCs may be cleared by performing one of the following:

Generic scan tool (follow manufacturer's instructions). If using Toyota Scan Tool, turn ignition switch from ON position to ACC, or OFF position while in CHECK MODE. If using Toyota Scan Tool, switch from NORMAL MODE to CHECK MODE or vice-versa.

SUMMARY NOTE: Always clear DTCs once repairs are complete. See CLEARING DIAGNOSTIC TROUBLE CODES . Road test vehicle and retrieve DTCs to determine if complaint or DTC is repaired.

If no hard DTCs are present, and driveability symptoms or intermittent DTCs exist, attempt diagnosis by symptom, or by testing individual components related to system fault. See TROUBLE SHOOTING and/or COMPONENT TESTS . If no problem is found, verify proper electronic control system circuit operation. See PIN VOLTAGE TESTS .

DIAGNOSTIC TESTS
When trouble shooting transaxle, first check for stored DTCs and repair as necessary. If no DTCs exist, perform manual shift test to determine if transaxle problem is electrically or mechanically related. See MANUAL SHIFT TEST under PERFORMANCE TESTS. DTC P0500: VEHICLE SPEED SENSOR FAULT NOTE: For circuit reference, see CONNECTOR IDENTIFICATION and/or WIRING DIAGRAMS .

Circuit Description

Vehicle Speed Sensor (VSS), driven by transaxle output shaft, outputs a 4-pulse signal to combination meter. Combination meter converts signal to a more precise waveform for ECM. DTC is set when ECM does not detect any signal while vehicle is in motion. Possible causes are:

Open or short in VSS circuit. VSS failure. Combination meter malfunction. ECM malfunction. Transaxle failure.

Diagnostic Procedure

2001-02 AUTOMATIC TRANSMISSIONS A-245E Diagnosis

1. Test drive vehicle and determine if speedometer is functioning properly. If speedometer is okay, go to next step. If speedometer is not okay, see VEHICLE SPEED SENSOR under COMPONENT TESTS. 2. Access ECM harness connectors behind console. Disconnect cruise control ECU connector. Cruise control ECU is located behind right kick panel. Shift transaxle into Neutral. Raise one front wheel. Turn ignition on. Using DVOM, backprobe between ground and terminal SPD at ECM harness connector. See WIRING DIAGRAMS . Rotate front wheel. 3. If voltage pulses between 4.5-5.5 volts, check for continuity between ECM harness connector terminal E1 and ground. If continuity does not exist, check and repair circuit as needed. If continuity does exist, replace ECM and retest. If voltage is not as specified, check and repair wiring harness or connector between combination meter and ECM. DTC P0750: NO. 1 SOLENOID FAULT OR DTC P0755: NO. 2 SOLENOID FAULT NOTE: For circuit reference, see CONNECTOR IDENTIFICATION and/or WIRING DIAGRAMS .

Circuit Description

ECM uses signal from crankshaft position sensor and vehicle speed sensor to determine actual gear position. ECM compares actual gear with shift schedule in memory to detect mechanical trouble of solenoids and/or valve body. DTC is set if during normal driving, gear required by ECM does not match actual gear after 2 trips have been completed. Possible causes are:

No. 1 and/or No. 2 solenoid is stuck open or closed. Valve body is clogged or valve(s) is stuck.

Diagnostic Procedure

Remove and inspect operation of solenoids. See SOLENOIDS under COMPONENT TESTS. If solenoids are okay, inspect valve body. See appropriate OVERHAUL article. DTC P0753: NO. 1 SOLENOID CIRCUIT OR DTC P0758: NO. 2 SOLENOID CIRCUIT NOTE: For circuit reference, see CONNECTOR IDENTIFICATION and/or WIRING DIAGRAMS .

Circuit Description

Shifting is performed in combination with ON and OFF position of shift solenoids controlled by ECM. If an open or short circuit occurs in either shift solenoid, ECM reverts to fail-safe mode. See Fig. 4 . DTCs are output when a open or short circuit occurs. Possible causes are:

No. 1 and/or No. 2 solenoid circuit. No. 1 and/or No. 2 solenoid. ECM malfunction.

Diagnostic Procedure

2001-02 AUTOMATIC TRANSMISSIONS A-245E Diagnosis

1. Ensure ignition is off. Access ECM. See Fig. 3 . Backprobing ECM harness connector with ohmmeter, measure resistance between ground and terminal S1 and/or S2. See PIN VOLTAGE TESTS . If resistance is 11-15 ohms, replace ECM and retest. If resistance is not 11-15 ohms, go to next step. 2. Disconnect appropriate ECM harness connector. Disconnect solenoid harness 3-pin connector (next to PNP switch) at transaxle. Check for continuity between terminal S1 of transaxle harness connector and corresponding terminal of ECM harness connector. Check for continuity between terminal S2 of transaxle harness connector and corresponding terminal of ECM harness connector. If continuity exists for both circuits, go to next step. If continuity does not exist for either circuit, inspect and repair circuit(s) as needed. 3. Measure resistance between ground and transaxle harness connector terminals S1 and/or S2. If resistance is 11-15 ohms, replace solenoid. If resistance is not 11-15 ohms, replace transaxle subharness as needed. DTC P0770: LOCK-UP SOLENOID NOTE: For circuit reference, see CONNECTOR IDENTIFICATION and/or WIRING DIAGRAMS .

Circuit Description

ECM uses signals from vehicle speed sensor, airflow meter, TP sensor and crankshaft position sensor to monitor engagement of Torque Converter Clutch (TCC). ECM compares engagement condition of TCC with lock-up schedule in memory to detect mechanical trouble of solenoid, valve body and torque converter. DTC is set when TCC lock-up does not occur at appropriate speed, or lock-up does not release at appropriate speed. Possible causes are:

SL solenoid is stuck open or closed. Valve body clogged or valve stuck. TCC malfunction.

Diagnostic Procedure

Remove and inspect operation of solenoid. See SOLENOIDS under COMPONENT TESTS. If solenoid is okay, inspect valve body. See appropriate OVERHAUL article. DTC P0773: LOCK-UP SOLENOID CIRCUIT NOTE: For circuit reference, see CONNECTOR IDENTIFICATION and/or WIRING DIAGRAMS .

Circuit Description

Lock-up (SL) solenoid is turned on and off by signals from ECM to control hydraulic pressure affecting lock-up relay valve. Lock-up relay valve controls operation of Torque Converter Clutch (TCC). If ECM detects a malfunction, fail-safe function is enabled. DTC is set when a open or short circuit occurs. Possible causes are:

SL solenoid open or short circuit.

2001-02 AUTOMATIC TRANSMISSIONS A-245E Diagnosis

SL solenoid malfunction. ECM malfunction.

Diagnostic Procedure

1. Ensure ignition is off. Access ECM. See Fig. 3 . Backprobing ECM harness connector with ohmmeter, measure resistance between ground and terminal SL. See PIN VOLTAGE TESTS . If resistance is 11-15 ohms, replace ECM and retest. If resistance is not 11-15 ohms, go to next step. 2. Disconnect appropriate ECM harness connector. Disconnect solenoid harness 3-pin connector (next to PNP switch) at transaxle. Check for continuity between terminal SL of transaxle harness connector and corresponding terminal of ECM harness connector. If continuity does not exist, inspect and repair circuit as needed. If continuity exists, measure resistance between ground and transaxle harness connector terminal SL. If resistance is 11-15 ohms, replace solenoid. If resistance is not 11-15 ohms, replace transaxle sub-harness as needed. DTC P1520: BRAKELIGHT SWITCH SIGNAL NOTE: For circuit reference, see CONNECTOR IDENTIFICATION and/or WIRING DIAGRAMS .

Circuit Description

Brakelight switch signal circuit is used to detect when brake pedal has been applied. Brakelight switch sends a signal to ECM when brake pedal is applied. This prevents engine stalling while driving in lock-up condition when brakes are suddenly applied. DTC is set when brakelight switch signal does not turn off even once when vehicle is driven. Possible causes are:

Short in brakelight switch signal circuit. Brakelight switch malfunction. ECM malfunction.

Diagnostic Procedure

1. Inspect operation of brakelights. Repair as needed. If switch is suspect, see BRAKELIGHT SWITCH under COMPONENT TESTS. If circuit is suspect, diagnose and repair as necessary. See WIRING DIAGRAMS . 2. Connect scan tool to Data Link Connector (DLC3). See Fig. 6 . Turn ignition on. Read STOP signal while depressing and releasing brake pedal. Ensure signal cycles when pressing brake pedal. If signal cycles, replace ECM. If signal does not cycle, check and repair circuit between brakelight switch and ECM. If circuit is okay, replace ECM. DTC P1780: PARK/NEUTRAL POSITION SWITCH NOTE: For circuit reference, see CONNECTOR IDENTIFICATION and/or WIRING DIAGRAMS .

Circuit Description

Park/Neutral Position (PNP) switch verifies shift lever position and sends signals to ECM. If no signal is

2001-02 AUTOMATIC TRANSMISSIONS A-245E Diagnosis

received from PNP switch, ECM defaults to drive ("D") position. DTC is set when ECM detects 2 or more circuits are on. Vehicle speed must be above 50 MPH for more than 30 seconds with engine RPM at 15005000. Possible causes are:

Short in PNP switch circuit. PNP switch malfunction. ECM malfunction.

Diagnostic Procedure

1. Turn ignition on. Access ECM. See Fig. 3 . Using DVOM, measure voltage between ground and terminals NSW, "R", "2" and "L" at ECM harness connector with shift lever in each shift position. See PIN VOLTAGE TESTS . 2. Ensure 7.5-14 volts is present at NSW terminal at ECM harness connector in all shift positions. Ensure 7.5-14 volts is present at "R", "2" and "L" terminals at ECM harness connector with shift lever in "R", "2" and "L" position. If voltage is not as specified, check park/neutral position switch. See PARK/NEUTRAL POSITION SWITCH under COMPONENT TESTS. If switch is okay, check and repair circuit(s) between PNP switch and ECM. See WIRING DIAGRAMS .

CIRCUIT TESTS
NOTE: For identification of electrical circuits and wire colors, see WIRING DIAGRAMS and CONNECTOR IDENTIFICATION . Perform appropriate circuit test based upon symptom vehicle exhibits. See CIRCUIT TEST DIRECTORY table.

NOTE:

CIRCUIT TEST DIRECTORY Symptom O/D OFF Indicator Always On O/D OFF Indicator Inoperative No 3-4 Upshift Or No 4-3 Downshift

Perform Circuit Test O/D SWITCH CIRCUIT O/D SWITCH CIRCUIT

(1) O/D SWITCH CIRCUIT & O/D CANCEL SIGNAL

CIRCUIT 3-4 Upshift With O/D Cancelled O/D SWITCH CIRCUIT (1) Perform O/D SWITCH CIRCUIT test before O/D CANCEL SIGNAL test. O/D CANCEL SIGNAL CIRCUIT 1. Access ECM. See Fig. 3 . Turn ignition on. Measure voltage (backprobe) between ground and terminal OD1 of ECM harness connector. See PIN VOLTAGE TESTS . If 9-14 volts is present, substitute ECM with known-good unit and retest. If voltage is not as specified, go to next step. 2. Turn ignition off. Disconnect cruise control ECU harness connector. ECU is located behind instrument panel on passenger side of vehicle. Turn ignition on. Measure voltage between terminal OD and ground. See Fig. 7 . If 9-14 volts is present, replace cruise control ECU and retest. If voltage is not as specified, inspect and repair circuit between cruise control ECU and ECM.

2001-02 AUTOMATIC TRANSMISSIONS A-245E Diagnosis

Fig. 7: Testing Cruise Control ECU Terminals Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. O/D SWITCH CIRCUIT 1. If directed here for O/D OFF indicator always on symptom, go to step 5 . If directed here for any other symptom, turn ignition off. Disconnect O/D switch 4-pin connector. Check for continuity between O/D switch connector terminals No. 2 and 4. See Fig. 9 . Continuity should not exist with O/D switch ON, and should exist with O/D switch OFF. If continuity is as specified, go to next step. If continuity is not as specified, replace O/D switch. 2. Remove instrument cluster and inspect O/D OFF indicator circuits and bulb. See appropriate INSTRUMENT PANELS article in ACCESSORIES & EQUIPMENT. Repair or replace instrument cluster as needed. If instrument cluster O/D OFF indicator circuits and bulb are okay, go to next step. 3. If a Toyota Scan Tool is not available, go to next step. If a Toyota Scan Tool is available, connect scan tool to Data Link Connector (DLC3). See Fig. 6 . Turn ignition on. Turn scan tool on. Monitor OVRDRIVE CUT SW2 signal on scan tool. OVRDRIVE CUT SW2 signal should be OFF with O/D switch depressed, and ON with O/D switch released. If OVRDRIVE CUT SW2 signal is not as specified, substitute ECM with known-good unit and retest. If OVRDRIVE CUT SW2 signal is as specified, inspect and repair circuit between O/D OFF indicator and ECM. If circuit is okay, replace ECM and retest. 4. Turn ignition on. Access ECM. See Fig. 3 . Using DVOM, measure voltage by backprobing between ECM 22-pin connector E6 terminal No. 7 and ground. Voltage should be less than one volt with O/D switch OFF and 10-14 volts with O/D switch ON. If voltage is not as specified, substitute ECM with known-good unit and retest. If voltage is as specified, inspect and repair circuit between O/D OFF

2001-02 AUTOMATIC TRANSMISSIONS A-245E Diagnosis

indicator and ECM. If circuit is okay, replace ECM and retest. 5. Turn ignition off. Disconnect O/D switch 4-pin connector. Check for continuity between O/D switch connector terminals No. 2 and 4. See Fig. 9 . Continuity should not exist with O/D switch ON, and should exist with O/D switch OFF. If continuity is not as specified, replace O/D switch. If continuity is as specified, inspect and repair circuit between O/D OFF indicator, O/D switch and ECM. If circuit is okay, replace ECM and retest.

COMPONENT TESTS
NOTE: For identification of electrical circuits and wire colors, see WIRING DIAGRAMS and CONNECTOR IDENTIFICATION . Not all components are used on all vehicles. Components identified for specific models are used only on those models.

NOTE:

BRAKELIGHT SWITCH Disconnect electrical connector from brakelight switch located near brake pedal. Using ohmmeter, ensure continuity exists between switch terminals No. 1 and 2 with brake pedal depressed. Continuity should exist between terminals No. 3 and 4 with pedal released. ENGINE COOLANT TEMPERATURE SENSOR Disconnect electrical connector from ECT sensor. ECT sensor is located in thermostat housing. Using ohmmeter, measure resistance between coolant temperature sensor terminals. Resistance should be as specified in accordance with coolant temperature. See Fig. 8 . Replace sensor if resistance is not within specification.

2001-02 AUTOMATIC TRANSMISSIONS A-245E Diagnosis

Fig. 8: Testing Engine Coolant Temperature Sensor Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.. O/D SWITCH Disconnect electrical connector from O/D switch located on shift lever. Note terminal identification on O/D switch. See Fig. 9 . Using ohmmeter, ensure continuity exists between terminals No. 2 and 4 with switch released (OFF position). Ensure continuity does not exist between terminals No. 2 and 4 with switch depressed (ON position). Replace switch if defective.

2001-02 AUTOMATIC TRANSMISSIONS A-245E Diagnosis

Fig. 9: Testing O/D Switch Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.. PARK/NEUTRAL POSITION SWITCH Disconnect harness connector at park/neutral position switch. Switch is located on side of transaxle. Using ohmmeter, check for continuity between specified terminals in accordance with shift lever position. See Fig. 10 . See PNP SWITCH CONTINUITY SPECIFICATIONS table. Replace PNP switch if defective.

2001-02 AUTOMATIC TRANSMISSIONS A-245E Diagnosis

Fig. 10: Testing Park/Neutral Position Switch Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.. PNP SWITCH CONTINUITY SPECIFICATIONS Switch Position P R N D 2 L SOLENOIDS To access solenoids, see LUBRICATION in SERVICING. 1. Access ECM. See Fig. 3 . Ensure ignition is off. Disconnect ECM harness connector. Using ohmmeter, measure resistance between ground and SL, S1 and S2 terminal for appropriate solenoid at ECM harness connector. Replace solenoid if resistance is not 11-15 ohms. Go to next step. 2. To check solenoid operation, apply battery voltage to SL, S1 or S2 terminal of ECM harness connector for appropriate solenoid. Ensure operating sound can be heard when battery voltage is connected. Replace solenoid if operating sound cannot be heard. Go to next step. 3. To check solenoid seals, remove suspect solenoid. See appropriate AUTOMATIC article in TRANSMISSION SERVICING. Connect battery voltage to solenoid. Apply 71 psi (5 kg/cm2 ) of compressed air to solenoid with battery voltage connected. See Fig. 11 . With battery voltage applied, air should pass through No. 1 and 2 solenoids. Disconnect voltage to solenoid. Ensure air does not pass through solenoid. Replace solenoid if defective. 4. With battery voltage applied, air should not pass through SL solenoid. Disconnect voltage to solenoid. Ensure air passes through solenoid. Replace solenoid if defective.

Check Continuity Between Terminals 3 & 9; 6 & 9 2&3 3 & 6; 6 & 9 3&7 3&4 3&8

Fig. 11: Testing Solenoid Operation Courtesy of TOYOTA MOTOR SALES, U.S.A., INC..

2001-02 AUTOMATIC TRANSMISSIONS A-245E Diagnosis

THROTTLE POSITION SENSOR Disconnect harness connector at throttle position sensor located on side of throttle body. Disconnect vacuum hose from throttle opener. Apply vacuum to throttle opener. Using ohmmeter, measure resistance between specified terminals in relation to throttle position. See Fig. 12 . See THROTTLE POSITION SENSOR RESISTANCE SPECIFICATIONS table. Replace throttle position sensor if resistance is not as specified.

Fig. 12: Testing Throttle Position Sensor Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. THROTTLE POSITION SENSOR RESISTANCE SPECIFICATIONS Terminals VC & E2 VTA & E2 Throttle Fully Closed Throttle Fully Open VEHICLE SPEED SENSOR 1. Disconnect electrical connector from speed sensor located on top of transaxle. See Fig. 3 . Connect positive battery lead to terminal No. 1 and negative lead to terminal No. 2. Connect positive lead of voltmeter to terminal No. 3 and negative lead to terminal No. 2. See Fig. 13 .

Ohms 2500-5900 200-5700 2000-10,200

2001-02 AUTOMATIC TRANSMISSIONS A-245E Diagnosis

2. Rotate speedometer cable shaft on speed sensor. Ensure voltage changes from zero to 11 volts. Voltage should change 4 times per each revolution of speedometer cable shaft. Replace speed sensor if voltage does not change as specified.

Fig. 13: Testing Vehicle Speed Sensor Courtesy of TOYOTA MOTOR SALES, U.S.A., INC..

REMOVAL & INSTALLATION

WARNING: Vehicle is equipped with Supplemental Inflatable Restraint (SIR) system. When servicing the vehicle, use care to avoid accidental air bag deployment. SIR system-related components are located in various locations throughout interior and exterior of vehicle, depending on application. Do not use electrical test equipment on or near these circuits. If necessary, deactivate SIR system before servicing components. See AIR BAG DEACTIVATION PROCEDURES article in GENERAL INFORMATION. CAUTION: When battery is disconnected, vehicle computer and memory systems may lose memory data. Driveability problems may exist until computer systems have completed a relearn cycle. See COMPUTER RELEARN PROCEDURES article in GENERAL INFORMATION before disconnecting battery.

2001-02 AUTOMATIC TRANSMISSIONS A-245E Diagnosis

BRAKELIGHT SWITCH
Removal & Installation

1. Disconnect electrical connector. Remove lock nut, and unscrew brakelight switch. To install, screw brakelight switch inward until brakelight plunger contacts brake pedal. 2. Install and tighten lock nut on brakelight switch. Install electrical connector. Ensure brakelights and cruise control (if equipped) operate properly. ENGINE COOLANT TEMPERATURE SENSOR
Removal & Installation

Coolant temperature sensor is located in thermostat housing. Drain cooling system and remove sensor. To install, reverse removal procedure. Tighten sensor to 15 ft. lbs. (20 N.m). Fill cooling system and check for leaks. O/D SWITCH NOTE: O/D switch is mounted on the shift lever. Replacement information is not available from manufacturer.

PARK/NEUTRAL POSITION SWITCH

Removal

Park/neutral position switch is located on side of transaxle. Remove lock nut, washer and manual lever from control shaft. See Fig. 14 . Bend up tabs on lock washer. Remove lock nut, lock washer and seal from control shaft. Remove retaining bolts and park/neutral position switch.
Installation

1. Install switch on control shaft. Loosely install park/neutral position switch retaining bolts. Install seal and lock washer. Install lock nut and tighten to specification. See TORQUE SPECIFICATIONS . Bend tabs on lock washer over against lock nut. 2. Ensure parking brake is applied. Temporarily install manual lever on control shaft. Place shift lever in Neutral. Remove manual lever. Rotate switch and align reference mark on PNP switch with groove. See Fig. 14 . 3. Hold park/neutral position switch in this position. Tighten retaining bolts to specification. To install remaining components, reverse removal procedure.

2001-02 AUTOMATIC TRANSMISSIONS A-245E Diagnosis

Fig. 14: Removing & Installing PNP Switch Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.. PATTERN SELECT SWITCH NOTE: Pattern select switch is located on center console. Replacement information is not available from manufacturer.

SOLENOIDS
Removal & Installation

Solenoids are located on transaxle valve body. Remove transaxle oil pan. See LUBRICATION in appropriate AUTOMATIC article in TRANSMISSION SERVICING. Remove bolt, solenoid and "O" ring from valve body. To install, reverse removal procedure using NEW "O" ring.

2001-02 AUTOMATIC TRANSMISSIONS A-245E Diagnosis

VEHICLE SPEED SENSOR

Removal

Disconnect electrical connector from speed sensor located on transaxle. Remove bolt, retaining plate and vehicle speed sensor. Remove "O" ring from speed sensor.
Installation

To install, reverse removal procedure using NEW "O" ring. Coat "O" ring with ATF before installing speed sensor. Tighten retaining bolt to specification. See TORQUE SPECIFICATIONS .

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS Application Vehicle Speed Sensor Bolt Park/Neutral Position Switch Bolt Lock Nut Ft. Lbs. (N.m) 12 (16) INCH Lbs. (N.m) 48 (5) 62 (7)

CONNECTOR IDENTIFICATION

Fig. 15: Identifying Brakelight Switch Terminals Courtesy of TOYOTA MOTOR SALES, U.S.A., INC..

2001-02 AUTOMATIC TRANSMISSIONS A-245E Diagnosis

Fig. 16: Identifying Coolant Temperature Sensor Connector Terminals Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2001-02 AUTOMATIC TRANSMISSIONS A-245E Diagnosis

Fig. 17: Identifying Cruise Control Module Connector Terminals Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2001-02 AUTOMATIC TRANSMISSIONS A-245E Diagnosis

Fig. 18: Identifying ECM Connector (E4) Terminals Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2001-02 AUTOMATIC TRANSMISSIONS A-245E Diagnosis

Fig. 19: Identifying ECM Connector (E5) Terminals Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2001-02 AUTOMATIC TRANSMISSIONS A-245E Diagnosis

Fig. 20: Identifying ECM Connector (E6) Terminals Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2001-02 AUTOMATIC TRANSMISSIONS A-245E Diagnosis

Fig. 21: Identifying ECM Connector (E7) Terminals Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2001-02 AUTOMATIC TRANSMISSIONS A-245E Diagnosis

Fig. 22: Identifying ECM Connector (E8) Terminals Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2001-02 AUTOMATIC TRANSMISSIONS A-245E Diagnosis

Fig. 23: Identifying ECM Connector (E9) Terminals Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2001-02 AUTOMATIC TRANSMISSIONS A-245E Diagnosis

Fig. 24: Identifying ECM Connector (E10) Terminals Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2001-02 AUTOMATIC TRANSMISSIONS A-245E Diagnosis

Fig. 25: Identifying Throttle Position Sensor Connector Terminals Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2001-02 AUTOMATIC TRANSMISSIONS A-245E Diagnosis

Fig. 26: Identifying Transaxle Solenoid Connector Terminals Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2001-02 AUTOMATIC TRANSMISSIONS A-245E Diagnosis

Fig. 27: Identifying Vehicle Speed Sensor Connector Terminals Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

PIN VOLTAGE TESTS

Access the ECM located in engine compartment, near battery. See Fig. 3 . Turn ignition switch to ON position. Using a DVOM, backprobe appropriate ECM harness connector. Check voltage between selected terminals. See Fig. 28 . Voltage should be as specified.

2001-02 AUTOMATIC TRANSMISSIONS A-245E Diagnosis

Fig. 28: Identifying ECM Connector Terminals & Pin Voltages Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

DIAGNOSIS - A-245E Fig. 29: Transaxle Electronic Control System Wiring Diagram (2001-02 Corolla)

2001-02 AUTOMATIC TRANSMISSIONS A-131L Overhaul

2001-02 AUTOMATIC TRANSMISSIONS A-131L Overhaul

APPLICATION
NOTE: Chevrolet Prizm is covered in this article due to limited use of this model transaxle in domestic vehicles. CAUTION: Flush oil cooler and oil cooler lines prior to transaxle installation. Oil cooling system contamination may cause premature transaxle failure. TRANSAXLE APPLICATION Application Chevrolet Prizm Toyota Corolla

Transaxle Model A-131L A-131L

IDENTIFICATION
TRANSAXLE This transaxle may be manufactured by either Aisin-Warner (AW) or Toyota. On Chevrolet Prizm, transaxle identification number is located above left drive axle. Transaxle is manufactured by Aisin-Warner or Toyota. On Corolla, transaxle identification number is located on converter housing (Aisin-Warner), or on top of transaxle case, above left drive axle (Toyota). See Fig. 1 -Fig. 3 .

2001-02 AUTOMATIC TRANSMISSIONS A-131L Overhaul

Fig. 1: Locating Transaxle Identification Number (Aisin Warner) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2001-02 AUTOMATIC TRANSMISSIONS A-131L Overhaul

Fig. 2: Locating Transaxle Identification Number (Toyota A-131L & A-132L) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2001-02 AUTOMATIC TRANSMISSIONS A-131L Overhaul

Fig. 3: Locating Transaxle Identification Number (Prizm) Courtesy of GENERAL MOTORS CORP. GEAR RATIOS TRANSAXLE GEAR RATIOS Gear Range 1st 2nd 3rd Reverse

Gear Ratio 2.810:1 1.549:1 1.000:1 2.296:1

DESCRIPTION & OPERATION

2001-02 AUTOMATIC TRANSMISSIONS A-131L Overhaul

INTRODUCTION Transaxle has 3 forward speeds and reverse. Transaxle assembly consists of torque converter, oil pump, valve body assembly, differential, input shaft, intermediate shaft, 2 planetary gear sets, 2 clutch style brakes, forward clutch, direct clutch and 2 one-way clutches. See Fig. 4 .

Fig. 4: Identifying Transaxle Component Locations Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

LUBRICATION
NOTE: See appropriate SERVICING article.

TROUBLE SHOOTING
NOTE: Transaxle malfunctions may be caused by poor engine performance, improper adjustments, fluid condition or failure of hydraulic, mechanical or electronic components. Ensure all concerns have been properly checked prior to transaxle overhaul. See appropriate DIAGNOSIS article.

2001-02 AUTOMATIC TRANSMISSIONS A-131L Overhaul

COMPONENT TESTS
TORQUE CONVERTER NOTE: Torque converter is sealed unit and must be serviced as complete assembly. Perform following tests to check converter condition. Torque converter and oil cooler lines must be thoroughly cleaned and flushed if transaxle fluid is contaminated.

One-Way Clutch Test

1. Install turner and stopper of One-Way Clutch Tester (09350-32014) in torque converter. See Fig. 5 . Turner fits in inner race of one-way clutch. Stopper fits in notch of converter hub and outer race of one-way clutch. 2. Clutch should lock when rotated counterclockwise, and turn freely when rotated clockwise. If necessary, clean converter and retest clutch. Replace converter if clutch does not test as described.

Fig. 5: Checking Torque Converter One-Way Clutch Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Drive Plate Runout Test

Measure drive plate runout. See Fig. 6 . If runout exceeds .008" (.20 mm), or if ring gear is damaged, replace drive plate. If installing a NEW drive plate, note position of spacers. Tighten bolts to specification. See TORQUE SPECIFICATIONS .
Converter Sleeve Runout Test

2001-02 AUTOMATIC TRANSMISSIONS A-131L Overhaul

1. Temporarily mount torque converter to drive plate. Mount a dial indicator with needle resting on converter sleeve. See Fig. 7 . Rotate converter. If runout exceeds .012" (.30 mm), ensure converter is properly mounted to drive plate. 2. If converter is properly mounted and runout exceeds specification, replace torque converter. Mark position of converter on drive plate to ensure correct installation. Remove converter from drive plate.

Fig. 6: Checking Drive Plate Runout Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2001-02 AUTOMATIC TRANSMISSIONS A-131L Overhaul

Fig. 7: Checking Converter Sleeve Runout Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

TRANSAXLE DISASSEMBLY
1. Remove oil cooler pipes and unions, manual shift lever and park/neutral position switch. Remove filler tube and dipstick. Remove throttle cable retaining plate. Remove governor cover bracket. Remove governor cover and "O" ring. Remove thrust washer. Remove governor assembly, plate washer and governor body adapter. See Fig. 8 . 2. Remove oil pan and gasket. Remove magnets from oil pan. Remove oil tube bracket and oil strainer. See Fig. 9 . Note location of oil tubes. Using large screwdriver, remove oil tubes. 3. Remove detent spring. Remove manual valve and manual valve body. See Fig. 10 . Note bolt length and location. Remove valve body assembly bolts. See Fig. 11 . Remove throttle cable from transaxle case. Remove 2nd brake (governor) apply gasket and governor oil strainer. See Fig. 12 . 4. Loosen accumulator cover bolts evenly until spring tension is released. Remove cover and gasket. See Fig. 9 . Remove forward clutch and direct clutch accumulator pistons and springs. Apply 14 psi (1 kg/cm2 ) of compressed air to oil passage to force 2nd brake piston and springs from bore. See Fig. 13 .

2001-02 AUTOMATIC TRANSMISSIONS A-131L Overhaul

Fig. 8: Identifying Transaxle External Components Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2001-02 AUTOMATIC TRANSMISSIONS A-131L Overhaul

Fig. 9: Removing Oil Pan, Oil Strainer & Accumulator Components Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2001-02 AUTOMATIC TRANSMISSIONS A-131L Overhaul

Fig. 10: Identifying Manual Valve Body Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 11: Identifying Valve Body Assembly Bolts

2001-02 AUTOMATIC TRANSMISSIONS A-131L Overhaul

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 12: Removing 2nd Brake Apply Gasket & Governor Oil Strainer Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2001-02 AUTOMATIC TRANSMISSIONS A-131L Overhaul

Fig. 13: Removing 2nd Brake Accumulator Piston & Springs Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 5. Apply small amount of paint to 2nd coast brake piston rod at point that it meets transaxle case. Using appropriate feeler gauge, measure 2nd coast brake piston stroke by applying and releasing compressed air to oil passage in transaxle case. See Fig. 43 . Note reading for reassembly reference. Piston stroke should be .059-.118" (1.50-3.00 mm). Remove snap ring. Remove 2nd coast brake piston cover. Remove 2nd coast brake piston and outer return spring. 6. Remove oil pump bolts. Using appropriate puller, pull oil pump free from case. Hold input shaft, grasp pump stator shaft and remove oil pump and direct clutch from transaxle case. Firmly push 2nd coast brake band into transaxle case. Ensure brake band does not catch on direct clutch drum. Remove direct clutch and thrust washer from rear of oil pump. 7. Remove forward clutch. Remove race and thrust bearings from forward clutch. Using small screwdriver, push 2nd coast brake band pin inward and remove from oil pump mounting bolt hole. Remove 2nd coast brake band. Remove front planetary ring gear. See Fig. 14 . Remove bearing and race from ring gear. 8. Remove front planetary gear. Remove bearings and races from planetary gear. Remove sun gear, sun gear input drum, 2nd brake hub and No. 1 one-way clutch. Remove 2nd coast brake band guide. Remove 2nd brake drum snap ring. Remove 2nd brake drum. Remove 2nd brake piston return spring. 9. Remove plates, discs and flange. Note number and location of components. Remove 2nd brake drum gasket. Remove No. 2 one-way clutch snap ring. Remove No. 2 one-way clutch and rear planetary gear. Remove thrust washers from both sides of planetary gear. Remove rear planetary ring gear, races

2001-02 AUTOMATIC TRANSMISSIONS A-131L Overhaul

and thrust bearings. Using compressed air, confirm 1st and reverse brake piston moves smoothly. See Fig. 15 . 10. Remove flange snap ring. Remove flange, plates and discs. Note number and location of components. Remove transaxle rear cover bolts. Tap rear cover using a plastic hammer. Remove cover. Remove intermediate shaft. Remove snap ring. Using appropriate spring compressor, remove snap ring and piston return spring from transaxle case. Apply compressed air into oil passage. Remove 1st and reverse brake piston. See Fig. 15 and Fig. 16 . 11. Remove parking lock pawl bracket. Remove parking lock rod. Remove pin, spring and parking lock pawl. Remove manual valve shaft spring, collar and pin. Remove manual valve lever from transaxle case. Remove manual shaft oil seal. Remove governor pressure adapter from transaxle case. See Fig. 14 .

Fig. 14: Exploded View Of Transaxle Internal Components Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2001-02 AUTOMATIC TRANSMISSIONS A-131L Overhaul

Fig. 15: Removing 1st & Reverse Brake Piston Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2001-02 AUTOMATIC TRANSMISSIONS A-131L Overhaul

Fig. 16: Exploded View Of 1st & Reverse Brake Piston Courtesy of TOYOTA MOTOR SALES, U.S.A. INC.

COMPONENT DISASSEMBLY & REASSEMBLY

OIL PUMP ASSEMBLY
Disassembly

1. Remove race from stator shaft. Remove "O" ring and oil seal rings from pump body and stator shaft. Remove clutch drum thrust washer from stator shaft. 2. Mark stator shaft and pump body for reassembly reference. Remove stator shaft bolts. Separate stator shaft and pump body. Mark gear location for reassembly reference. Remove pump gears. Using screwdriver, remove oil seal. See Fig. 17 .

2001-02 AUTOMATIC TRANSMISSIONS A-131L Overhaul

Fig. 17: Exploded View Of Oil Pump Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Inspection

1. Clean all parts with solvent. Use compressed air to ensure oil passages are clear. Install oil pump gears into pump body. Check driven gear-to-body clearance. Push driven gear against one side of pump. Using a feeler gauge, measure clearance between driven gear and pump body. See Fig. 18 . Replace pump body if clearance is not within specification. See OIL PUMP CLEARANCE SPECIFICATIONS table. 2. Using a feeler gauge, measure tip clearance between both gears and crescent-shaped part of pump body. See Fig. 19 . Replace pump body if clearance is not within specification. See OIL PUMP CLEARANCE SPECIFICATIONS table. 3. Using a feeler gauge and straightedge, measure side clearance of both gears. See Fig. 20 . Replace pump body if clearance is not within specification. See OIL PUMP CLEARANCE SPECIFICATIONS table. Drive and driven gears are available in 3 different thicknesses. See DRIVE & DRIVEN GEAR THICKNESS SPECIFICATIONS table. OIL PUMP CLEARANCE SPECIFICATIONS Application In. (mm) Driven Gear-To-Pump Body Standard .0028-.0059 (.071-.149) Maximum .012 (.30) Gear-To-Crescent Tip Clearance Standard .0043-.0055 (.109-.139) Maximum .012 (.30) Gear Side Clearance Standard .0008-.0020 (.020-.050) Maximum .004 (.10)

2001-02 AUTOMATIC TRANSMISSIONS A-131L Overhaul

DRIVE & DRIVEN GEAR THICKNESS SPECIFICATIONS I.D. Mark In. (mm) A .3717-.3723 (9.440-9.456) B .3723-.3730 (9.456-9.474) C .3730-.3736 (9.474-9.490) 4. Using a dial indicator, measure inside diameter of oil pump body bushing. Maximum inside diameter is 1.503" (38.18 mm). If inside diameter exceeds specification, replace oil pump body. 5. Using a dial indicator, measure inside diameter of stator shaft bushings. Maximum front side bushing inside diameter is .849" (21.57 mm). Maximum rear side bushing inside diameter is 1.066" (27.07 mm). If inside diameter exceeds specification, replace stator shaft.
Reassembly

1. Install NEW oil seal. Seal must be even with edge of pump body. Coat all components with ATF. Install pump gears (if necessary), aligning reference marks. Install stator shaft on pump body. Align bolt holes and tighten bolts to 89 INCH lbs. (10 N.m). Coat thrust washer with petroleum jelly. 2. Install thrust washer on pump body. Align washer tab with hollow of pump body. Install oil seal rings. Ensure rings rotate smoothly after installation. DO NOT spread oil seal ring ends more than necessary for installation. Using screwdrivers, check drive gear for smooth rotation. Install "O" ring. Install race on stator shaft. See Fig. 17 .

Fig. 18: Checking Oil Pump Driven Gear Clearance Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2001-02 AUTOMATIC TRANSMISSIONS A-131L Overhaul

Fig. 19: Checking Oil Pump Gear Tip Clearance Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2001-02 AUTOMATIC TRANSMISSIONS A-131L Overhaul

Fig. 20: Checking Oil Pump Gear Side Clearance Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. DIRECT CLUTCH
Disassembly

1. Remove snap ring from clutch drum. Remove flange, discs and plates. Note number and location of components. See Fig. 21 . Using appropriate clutch spring compressor, compress piston return springs. Remove snap ring, clutch spring compressor, spring retainer and piston return spring. 2. Install direct clutch on oil pump. Apply compressed air to oil pump oval shaped passage to remove piston. See Fig. 22 . Remove direct clutch from oil pump. Remove clutch piston "O" rings.

2001-02 AUTOMATIC TRANSMISSIONS A-131L Overhaul

Fig. 21: Exploded View Of Direct Clutch Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2001-02 AUTOMATIC TRANSMISSIONS A-131L Overhaul

Fig. 22: Checking Direct Clutch Piston Stroke Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Inspection

1. Clean all parts (except discs) with solvent. Dry parts using compressed air. Ensure check ball is free in

2001-02 AUTOMATIC TRANSMISSIONS A-131L Overhaul

piston. Apply low air pressure to small hole in piston to check for air leakage around piston valve. Inspect discs and plates for wear or burnt areas. 2. If disc lining is peeled or discolored, replace discs as necessary. Replace all damaged components. Using a dial indicator, measure inside diameter of direct clutch bushing. Maximum inside diameter is 1.853" (47.07 mm). If inside diameter exceeds specification, replace direct clutch drum. NOTE:
Reassembly

New discs must be soaked in ATF for 15 minutes prior to reassembly.

1. Install NEW "O" rings on piston and coat with ATF. Using hand pressure, press direct clutch piston into clutch drum with cup side up. Install piston return spring and retainer. Compress piston return spring and install snap ring. 2. Ensure snap ring gap does not align with spring retainer claw. Install plates, discs, and flange. Install flange with flat side facing downward. Install snap ring. Ensure snap ring gap does not align with drum cutout. 3. Install direct clutch on oil pump. Use dial indicator to check direct clutch piston stroke. Apply air pressure to oil pump passage and note reading. See Fig. 22 . Clutch piston stroke should be .054.067" (1.37-1.70 mm). If piston stroke is not as specified, select appropriate flange to obtain correct piston stroke. Flange is available in thicknesses of .118" (3.00 mm) and .133" (3.37 mm). FORWARD CLUTCH
Disassembly

1. Remove thrust washer. Remove races and thrust bearings from both sides of clutch drum. Remove clutch drum snap ring. Remove flange, discs and plates. Note number and location of components. See Fig. 23 . 2. Using appropriate clutch spring compressor, compress piston return spring. Remove snap ring. Remove spring compressor and piston return spring. 3. To remove forward clutch piston, apply compressed air to oil passage hole (nearest piston) on rear of forward clutch shaft. Remove oil seal rings (if necessary).

2001-02 AUTOMATIC TRANSMISSIONS A-131L Overhaul

Fig. 23: Exploded View Of Forward Clutch Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A. INC.
Inspection

Clean all parts (except discs) with solvent. Dry parts using compressed air. Ensure check ball is free in piston. Apply low air pressure to small hole in piston to check for air leakage around piston valve. Inspect discs and plates for wear or burnt areas. If disc lining is peeled or discolored, replace discs as necessary. Replace all damaged components. NOTE:
Reassembly

New discs must be soaked in ATF 15 for minutes prior to reassembly.

1. Install NEW seal rings (if necessary). Use care not to over expand seal rings. Install NEW "O" rings on piston and coat with ATF. Using hand pressure, install piston in clutch drum with cup side upward. 2. Install piston return spring. Compress piston return spring using clutch spring compressor. Install snap ring. Ensure snap ring gap does not align with spring retainer claw. 3. Install plates and discs in appropriate order. See Fig. 23 . Install flange with flat side facing downward. Install snap ring. Ensure snap ring gap does not align with drum cutout. 4. Position dial indicator tip on flange. Measure piston stroke by applying compressed air to oil passage hole (nearest piston) on rear of forward clutch shaft and note reading. Clutch piston stroke should be .044-.058" (1.11-1.47 mm). 5. If piston stroke is not as specified, select appropriate flange to obtain correct piston stroke. Flange is available in thicknesses of .118" (3.00 mm) and .133" (3.37 mm). Coat thrust washer, races and

2001-02 AUTOMATIC TRANSMISSIONS A-131L Overhaul

bearing with petroleum jelly and install. FRONT PLANETARY GEAR

Disassembly

1. Check No. 1 one-way clutch operation. Hold sun gear and rotate hub. Hub should rotate freely in clockwise direction and lock when rotated in counterclockwise direction. See Fig. 24 . Turn hub clockwise and remove 2nd brake hub and one-way clutch from sun gear. 2. Remove thrust washer and snap ring. Remove sun gear from input drum. Remove shaft snap ring from sun gear. Remove one-way clutch retainer if clutch requires replacement. Remove one-way clutch from hub.

Fig. 24: Checking No. 1 One-Way Clutch Courtesy of TOYOTA MOTOR SALES, U.S.A. INC.
Inspection

1. Clean all parts with solvent. Dry parts using compressed air. Check thrust bearings, races and one-way clutch for wear or damage. Replace if necessary. 2. Using a dial indicator, measure inside diameter of sun gear bushing. Standard inside diameter should be .867-.868" (22.03-22.05 mm). Maximum inside diameter is .870" (22.10 mm). If inside diameter exceeds specification, replace sun gear.

2001-02 AUTOMATIC TRANSMISSIONS A-131L Overhaul

3. Using a feeler gauge, measure clearance between planetary pinion gear and planetary gear case. Standard clearance should be .008-.020" (.20-.50 mm). Maximum clearance is .020" (.50 mm). If clearance exceeds specification, replace planetary gear. 4. Using a dial indicator, measure inside diameter of ring gear flange bushing. Standard inside diameter should be .749-.750" (19.03-19.05 mm). If inside diameter exceeds specification, replace flange.
Reassembly

Install shaft snap ring to sun gear. Install sun gear to drum. Install snap ring to drum. Install thrust washer to sun gear input drum. See Fig. 25 . Rotate hub clockwise. Install one-way clutch and 2nd brake hub. Hold sun gear and rotate hub. Hub should rotate freely in clockwise direction and lock when rotated in counterclockwise direction.

2001-02 AUTOMATIC TRANSMISSIONS A-131L Overhaul

Fig. 25: Exploded View Of Front Planetary Gear Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A. INC. REAR PLANETARY GEAR
Disassembly

1. Check No. 2 one-way clutch operation. Hold outer race and rotate hub. Hub should rotate freely in counterclockwise direction and lock when rotated in clockwise direction. See Fig. 26 .

2001-02 AUTOMATIC TRANSMISSIONS A-131L Overhaul

2. Remove thrust washers from both sides of rear planetary gear. Separate No. 2 one-way clutch and planetary gear. Remove snap rings and retainers from No. 2 one-way clutch. Note position of No. 2 one-way clutch. Remove one-way clutch from outer race.
Inspection

1. Clean all parts with solvent. Dry parts using compressed air. Check thrust washers and one-way clutch for wear or damage. Replace if necessary. 2. Using a feeler gauge, measure clearance between planetary pinion gear and planetary gear case. Standard clearance should be .008-.020" (.20-.50 mm). Maximum clearance is .020" (.50 mm). If clearance exceeds specification, replace planetary gear.
Reassembly

1. Coat all parts with ATF. Install one-way clutch into outer race. Flanged side of one-way clutch should face toward shiny side of outer race. See Fig. 26 . Install retainers and snap rings. 2. Install planetary gear into one-way clutch. Planetary gear inner race should face toward back side of outer race. Check operation of one-way clutch. Coat thrust washers with petroleum jelly. Install thrust washers on both sides of planetary gear. Ensure thrust washer tab is aligned with hollow area in gear. See Fig. 27 .

2001-02 AUTOMATIC TRANSMISSIONS A-131L Overhaul

Fig. 26: Checking & Installing No. 2 One-Way Clutch Courtesy of TOYOTA MOTOR SALES, U.S.A. INC.

2001-02 AUTOMATIC TRANSMISSIONS A-131L Overhaul

Fig. 27: Exploded View Of Rear Planetary Gear Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A. INC. 1ST & REVERSE BRAKE PISTON
Disassembly

Using appropriate spring compressor, compress springs by tightening bolt gradually. Remove snap ring and compressor. Remove piston return spring. Apply compressed air to oil passage in transaxle case to remove piston. See Fig. 15 . Remove piston "O" rings.
Inspection

Clean all parts with solvent. Dry parts using compressed air. Inspect piston for roughness or damage. Replace as necessary.
Reassembly

2001-02 AUTOMATIC TRANSMISSIONS A-131L Overhaul

1. Install NEW "O" rings on piston and coat with ATF. Install piston in transaxle case with spring seats facing upward. Install piston return spring and snap ring in place. Using clutch spring compressor, compress piston return spring. Avoid bending spring retainer or damaging transaxle case by overtightening compressor. 2. Push snap ring into place with fingers. Ensure snap ring is fully seated and centered by spring retainer lugs. Snap ring end gap must not align with spring retainer claw. Remove spring compressor. See Fig. 16 . 2ND COAST BRAKE
Disassembly

Remove oil seal ring from piston. Remove "E" ring from piston with needle-nose pliers. Remove spring, washer and piston rod. See Fig. 28 .
Inspection

Replace brake band if lining is peeled, discolored or printed numbers are defaced. Before assembling NEW band, soak in ATF for 15 minutes. If band is serviceable but piston rod stroke is not within specification, select a NEW piston rod. Piston stroke should be .059-.118" (1.50-3.00 mm). Piston rods are available in lengths of 2.811" (71.40 mm) and 2.870" (72.90 mm).
Reassembly

Install washer and spring to piston rod. Install "E" ring while pushing piston. Apply ATF to oil seal ring. Install oil seal ring to piston. DO NOT spread oil seal ring ends more than necessary for installation. See Fig. 28 .

2001-02 AUTOMATIC TRANSMISSIONS A-131L Overhaul

Fig. 28: Exploded View Of 2nd Coast Brake Courtesy of TOYOTA MOTOR SALES, U.S.A. INC. 2ND BRAKE PISTON
Disassembly & Reassembly

Apply compressed air to oil hole on 2nd brake drum and remove 2nd brake piston. Remove 2 "O" rings from piston. Coat NEW "O" rings with ATF. Install "O" rings on piston. Using hand pressure, carefully press 2nd brake piston into 2nd brake drum. See Fig. 29 .

2001-02 AUTOMATIC TRANSMISSIONS A-131L Overhaul

Fig. 29: Exploded View Of 2nd Brake Piston Courtesy of TOYOTA MOTOR SALES, U.S.A. INC. INTERMEDIATE SHAFT
Disassembly & Reassembly

Using appropriate bearing splitter and puller or press, remove intermediate shaft bearings from shaft. Install intermediate shaft bearings. Ensure gear flange end to intermediate shaft end measurement is 4.560" (115.82 mm). See Fig. 30 .

Fig. 30: Checking Intermediate Shaft Gear Flange Courtesy of TOYOTA MOTOR SALES, U.S.A. INC.

2001-02 AUTOMATIC TRANSMISSIONS A-131L Overhaul

VALVE BODY ASSEMBLY NOTE: All valve body assembly components must be installed in original location. Lay all components in sequence during removal for reassembly reference. Throttle pressure is changed according to number of adjusting rings. See Fig. 31 . When assembling valve body, install same number of adjusting rings as were removed. Some valve bodies do not have adjusting rings.

Disassembly

Remove 9 bolts and upper valve body cover. Remove strainer, 2 gaskets and plate. Remove sleeve stopper. Remove 3 bolts and upper valve body. Remove 14 bolts, lower valve body cover and gasket. Remove 3 lower valve body bolts. Hold plate against lower valve body and carefully remove lower valve body. DO NOT lose check balls. Note location of check balls, retainers and pins in valve body. Remove plate and gasket. See Fig. 31 .

Fig. 31: Exploded View Of Valve Body Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A. INC.
Inspection

2001-02 AUTOMATIC TRANSMISSIONS A-131L Overhaul

1. Clean all parts with solvent. Dry parts with compressed air. Ensure all valve body oil passages are clear. Inspect valves for scoring or roughness. Inspect valve springs for damage, squareness, rust and collapsed coils. Measure spring free length and outer diameter. 2. Replace spring if not within specification. See appropriate VALVE BODY SPRING SPECIFICATIONS table. Ensure valve body springs correspond with appropriate valve. Ensure retainers are installed in appropriate locations. UPPER VALVE BODY SPRING SPECIFICATIONS Spring No. (1) Diameter - In. (mm) 1 .374 (9.50) 2 (Chevrolet) .409 (10.40) 2 (Toyota) .417 (10.60) 3 .311 (7.90) 4 (AW) .343 (8.70) 4 (Toyota) .343 (8.70) 5 .362 (9.20) 6 .335 (8.50) 7 .402 (10.20) (1) For spring locations, refer to illustration. See Fig. 32 . LOWER VALVE BODY SPRING SPECIFICATIONS Spring No. (1) Diameter - In. (mm) 1 .429 (10.90) 2 .252 (6.40) 3 .327 (8.30) 4 .315 (8.00) 5 (Chevrolet) .311 (7.90) 5 (Toyota) .311 (7.90) 6 (Chevrolet) .327 (8.30) 6 (Toyota) .732 (18.60) 7 .433 (11.00) 8 .252 (6.40) (1) For spring locations, refer to illustration. See Fig. 34 . Free Length - In. (mm) 1.717 (43.60) 1.071 (27.20) 1.091 (27.70) 1.236 (31.40) 1.201 (30.64) 1.146 (29.10) 2.624 (66.65) 2.626 (66.70) .783 (19.90) .441 (11.20) Free Length - In. (mm) .854 (21.70) 1.307 (33.20) 1.106 (28.10) .921 (23.40) 1.140 (28.95) 1.173 (29.80) 1.209 (30.70) .823 (20.90) 1.047 (26.60)

2001-02 AUTOMATIC TRANSMISSIONS A-131L Overhaul

Fig. 32: Exploded View Of Upper Valve Body Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2001-02 AUTOMATIC TRANSMISSIONS A-131L Overhaul

Fig. 33: Identifying Upper Valve Body Check Ball, Pin & Retainer Locations Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2001-02 AUTOMATIC TRANSMISSIONS A-131L Overhaul

Fig. 34: Exploded View Of Lower Valve Body Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2001-02 AUTOMATIC TRANSMISSIONS A-131L Overhaul

Fig. 35: Identifying Lower Valve Body Check Ball, Pin & Retainer Locations Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. NOTE: Valves may be held in with pins or retainers and plugs. Remove components and note locations. Arrange parts in order for reassembly reference.

Reassembly

1. Coat all components with ATF. To reassemble, reverse disassembly procedure. Ensure check balls, pins and strainer on upper side of lower valve body are installed correctly. See Fig. 35 . Ensure check ball, pins, retainers and vibrating stopper on lower side of upper valve body are installed correctly. See Fig. 33 . 2. Position NEW No. 2 gasket, plate and NEW No. 1 gasket on lower valve body. Ensure gaskets are installed in correct locations. See Fig. 36 . Place lower valve body with plate and gaskets on upper valve body. DO NOT allow components separate. Align each bolt hole in valve bodies with gaskets and plate. 3. Install and finger tighten bolts in lower valve body to secure upper valve body. See Fig. 37 . Install lower valve body cover over NEW gasket. Install and finger tighten 14 cover bolts. See Fig. 38 . Install and finger tighten 1.102" (28 mm) bolts (3) in upper valve body. 4. Ensure retainers are installed correctly on upper side of upper valve body. Install sleeve stopper. Position NEW gasket, plate and gasket. Install strainer onto plate. Position upper valve body cover and install and finger tighten 9 bolts. See Fig. 38 . Check alignment of gaskets and plates. Tighten upper and lower valve body bolts to 48 INCH lbs. (5.4 N.m).

2001-02 AUTOMATIC TRANSMISSIONS A-131L Overhaul

Fig. 36: Identifying Valve Body Gaskets Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2001-02 AUTOMATIC TRANSMISSIONS A-131L Overhaul

Fig. 37: Installing Lower Valve Body-To-Upper Valve Body Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2001-02 AUTOMATIC TRANSMISSIONS A-131L Overhaul

Fig. 38: Identifying Upper & Lower Valve Body Cover Bolt Locations Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2001-02 AUTOMATIC TRANSMISSIONS A-131L Overhaul

DIFFERENTIAL ASSEMBLY
Disassembly

1. Remove carrier cover. Attach an INCH-lb. torque wrench to end of pinion shaft. See Fig. 39 . Measure total preload required to rotate pinion. Note and record reading. Position dial indicator assembly on transaxle case. Position dial indicator tip against side gear. See Fig. 40 . Measure side gear backlash while holding one pinion toward case. Backlash should be .002-.008" (.05-.20 mm). Note and record reading. 2. Remove left side bearing retainer bolts. Remove bearing retainer. Remove "O" ring from retainer. Remove right side bearing cap. Remove differential, outer race and adjustment shim from transaxle case. 3. Attach an INCH-lb. torque wrench to end of pinion shaft. Measure drive pinion preload. Note and record reading. Starting preload should be 4-7 INCH lbs. (.5-.8 N.m) for a used bearing. Total preload reading minus drive pinion preload should equal 1-2 INCH lbs. (.1-.2 N.m). If not within specification, side bearing preload requires adjustment. 4. Remove bearings from differential case using appropriate puller. Remove speedometer drive gear. Mark ring gear and case for reassembly reference. Spread ring gear bolt locking plates. Remove ring gear bolts and locking plates. Using brass hammer, tap ring gear from differential case. 5. Using a dial indicator, check side gear backlash. Hold one pinion against case. Measure side gear backlash. Backlash must be .002-.008" (.05-.20 mm). If backlash is not within specification, side gear thrust washers must be replaced. 6. Drive out pinion shaft lock pin from ring gear side. Remove pinion shaft, pinion gears, side gears and thrust washers. Remove left oil seals from transaxle case or bearing retainer. Using a long screwdriver, remove right oil seal from transaxle case. Remove left outer bearing race and shim from retainer.

2001-02 AUTOMATIC TRANSMISSIONS A-131L Overhaul

Fig. 39: Measuring Total Preload Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2001-02 AUTOMATIC TRANSMISSIONS A-131L Overhaul

Fig. 40: Measuring Differential Side Gear Backlash Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Cleaning & Inspection

Clean all parts with solvent. Dry with compressed air. Check bearings and gears for wear or damage. Replace if necessary.
Reassembly

1. Install original shim onto retainer. Install outer race. Lubricate oil seal lip. Install oil seals until oil seal surface is flush with surface of transaxle case or bearing retainer. 2. Select thrust washers that will ensure correct side gear backlash. Thrust washers are available in thicknesses from .037" (.95 mm) to .047" (1.20 mm), in .20" (.05 mm) increments. Install thrust washers and side gears in differential case. If possible, install same size thrust washers on both sides. Install pinion gears and pinion shaft. Check side gear backlash to ensure proper thrust washers are used. 3. Once backlash is correct, using hammer and punch, drive lock pin through differential case and into pinion shaft. Stake differential case to retain lock pin. Install speedometer drive gear onto differential case. Install side bearings onto differential case. 4. Clean ring gear contact surface of differential case. Heat ring gear to 212F (100C) in an oil bath. DO NOT heat ring gear above 230F (110C). Clean contact surface of ring gear using cleaning solvent. Align ring gear with differential case. Install ring gear on differential case. 5. Install NEW locking plates and bolts. Tighten bolts evenly and in several steps to 72 ft. lbs. (97 N.m). Stake lock plates. Stake one tab flush with flat surface of bolt. Stake 2nd tab against corner of bolt.

2001-02 AUTOMATIC TRANSMISSIONS A-131L Overhaul

6. Install outer race and original adjusting shim on right side bearing. Remove differential drive pinion. See DIFFERENTIAL DRIVE PINION ASSEMBLY . Install differential in transaxle case. Install left bearing outer race, shim and retainer without "O" ring. Snug bolts evenly and gradually while turning ring gear. Tighten bolts to 14 ft. lbs. (19 N.m). Install right side bearing cap. Snug bolts evenly and gradually while turning ring gear. Tighten bolts to 36 ft. lbs. (49 N.m). 7. Using Differential Preload Adapter (09564-32011) and an INCH-lb. torque wrench, measure differential bearing preload with differential drive pinion removed. See Fig. 41 . Preload must be within specifications. See DIFFERENTIAL PRELOAD SPECIFICATIONS table. If preload is not within specifications, remove differential from transaxle case and replace adjustment shim at right side bearing with appropriate shim. 8. Adjustment shims are available in thicknesses from 063" (1.60 mm) to .104" (2.65 mm), in .20" (.05 mm) increments. Preload will change approximately 2.6-3.5 INCH lbs. (.3-.4 N.m) with each shim thickness. DIFFERENTIAL PRELOAD SPECIFICATIONS Application INCH Lbs. (N.m) New Bearings 9-14 (1.0-1.6) Used Bearings 4-7 (.5-.8)

Fig. 41: Measuring Differential Bearing Preload Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 9. If preload is within specification, remove left bearing retainer. DO NOT lose selected adjustment

2001-02 AUTOMATIC TRANSMISSIONS A-131L Overhaul

shim. Install "O" ring on left bearing retainer. Remove right side bearing cap bolts and coat threads with sealant. Tighten bolts evenly and gradually to 36 ft. lbs. (49 N.m) while turning ring gear. 10. With drive pinion installed in case, measure total preload using procedure used during disassembly. Starting preload should be drive pinion preload of 4-7 INCH lbs. (.5-.8 N.m) plus 3-4 INCH lbs. (.3-.4 N.m) for NEW bearings or 1-2 INCH lbs. (.1-.2 N.m) for used bearings. 11. If total preload is not within specification, disassemble differential and readjust. If total preload is correct, stake counter-driven gear lock nut. Install drive pinion cap. Coat carrier cover bolt threads with sealant. Install carrier cover and gasket. Install bolts and tighten to 18 ft. lbs. (25 N.m). To complete reassembly, reverse disassembly procedure. Tighten all bolts to specification. See Fig. 42 .

Fig. 42: Exploded View Of Differential Assembly, Drive Pinion & Case Components Courtesy of TOYOTA MOTOR SALES, U.S.A. INC. DIFFERENTIAL DRIVE PINION ASSEMBLY

2001-02 AUTOMATIC TRANSMISSIONS A-131L Overhaul

Disassembly

1. Using an INCH-lb. torque wrench, measure drive pinion preload with differential assembly removed. Starting preload should be 4-7 INCH lbs. (.5-.8 N.m) for used bearings. Remove drive pinion bolt and cap. Using chisel, loosen staked area of counter-driven gear lock nut. Secure gear from turning. Remove lock nut. Using appropriate puller, remove counter-driven gear and bearing. 2. Remove bearing race from transaxle case. Remove oil slinger, bearing spacer and governor drive gear. Remove snap ring from transaxle case. Using brass drift and hammer, drive pinion and bearing cage from bore. Press governor drive gear from drive pinion shaft. Remove bearing cage from drive pinion. Remove "O" ring from bearing cage. See Fig. 42 . 3. Press bearing from counter-driven gear. Using bearing remover, remove pinion shaft bearing. Using hammer and brass drift, drive out drive bearing outer race from cage. Note position of oil seal lips. Remove seals from cage.
Cleaning & Inspection

Clean all parts with solvent. Dry parts with compressed air. Check bearings and gears for wear or damage. Replace if necessary.
Reassembly

1. Lubricate lips of oil seals. Install inner seal with lip facing downward. Oil seal must be installed to proper depth of .315" (8.00 mm). 2. Using seal installer, install outer seal with lip facing upward. Position oil seal flush with cage surface. Install outer bearing race in bearing cage. 3. Install drive pinion shaft bearing. Using remover/installer, install bearing on counter-driven gear. Install "O" ring on bearing cage. Install cage on drive pinion shaft. Use care not to damage oil seals. Install governor drive gear. Install shaft assembly into transaxle case. 4. Tap bearing cage into transaxle case. Ensure cage is past snap ring groove. Install snap ring. Insert brass bar into hole and tap drive pinion shaft against snap ring. Ensure snap ring is fully seated. Install oil slinger with lip facing outward. Install outer race in transaxle case with narrow end facing out. Install NEW bearing spacer, small end first. 5. Drive counter-driven gear onto shaft until lock nut can be installed. DO NOT tap on transaxle case. Lubricate lock nut threads and install lock nut on shaft. Install holder on gear. Tighten counter-driven gear lock nut to 127 ft. lbs. (172 N.m). Rotate counter-driven gear both directions several times. 6. Using an INCH-lb. torque wrench, measure drive pinion preload. Starting preload should be 9-14 INCH lbs. (1.0-1.6 N.m) for NEW bearings and 4-7 INCH lbs. (.5-.8 N.m) for used bearings. Replace bearing spacer if preload exceeds specifications. Recheck preload procedure (if necessary). 7. If preload is less than specification, tighten lock nut in additional increments of 9.5 ft. lbs. (13 N.m). Tighten lock nut until specified preload is obtained. If maximum torque of 213 ft. lbs. (289 N.m) is exceeded while tightening nut, replace bearing spacer and repeat procedure. DO NOT back off nut to reduce preload.

TRANSAXLE REASSEMBLY
NOTE: Coat all oil seal rings, clutch discs, clutch plates, rotating parts and sliding surfaces with ATF prior to reassembly. Soak clutch discs in ATF for 15 minutes prior to installation. For bearing race and thrust bearing installation direction and locations, See Fig. 45 . For bearing race and thrust bearing

2001-02 AUTOMATIC TRANSMISSIONS A-131L Overhaul

outer diameter specifications, see BEARING RACE & THRUST BEARING SPECIFICATIONS table under ACCUMULATOR SPRING SPECIFICATIONS. 1. Install governor pressure adapter into case. Align adapter and transaxle case hole and install torsion spring. Ensure adapter does not slide and spring does not fall out when pulled. Install manual valve lever shaft oil seal to transaxle case. Install NEW collar on manual valve lever. See Fig. 42 . 2. Install manual valve lever shaft to transaxle case through manual valve lever. Using a pin punch, drive in roll pin until flush with manual valve lever surface. Align collar hole with notch in lever and stake in position using a hammer and punch. Install retaining spring. Ensure lever moves smoothly. 3. Install parking lock pawl in transaxle case. Hook spring end on pawl and transaxle case. Install pin into hole of transaxle case, through spring and pawl. Install parking lock rod. 4. Install parking lock pawl bracket. Tighten to 65 INCH lbs. (7.4 N.m). Check operation of parking lock pawl to ensure counter-driven gear is locked when manual valve lever is in "P" position. Install 1st and reverse brake piston (if necessary). See 1ST & REVERSE BRAKE PISTON under COMPONENT DISASSEMBLY & REASSEMBLY. Install intermediate shaft. Install transaxle rear cover and gasket. Tighten bolts to 18 ft. lbs. (25 N.m). 5. Ensure intermediate shaft turns smoothly. Using a dial indicator, check intermediate shaft end play. End play should be .019-.059" (.49-1.51 mm). If end play is not as specified, check installation of intermediate shaft. On Aisin-Warner transaxles, install discs and plates starting with plate, alternating with disc and ending with disc. On Toyota transaxles, install 1st and reverse brake inner flange with flat end facing upward. Install discs and plates starting with disc, alternating with plate and ending with disc. 6. On both transaxles, install outer flange with flat side toward piston. Install snap ring. Ensure end gap of snap ring is not aligned with cutout of transaxle case. Apply compressed air to oil passage to ensure piston moves. See Fig. 15 . Coat bearings and races "E" with petroleum jelly and install on ring gear. See Fig. 45 . Install ring gear in transaxle case. 7. Align flukes of discs in 1st and reverse brake. Coat thrust washer with petroleum jelly. Align tab of thrust washer with hollow of planetary carrier. Align planetary carrier splines with flukes of discs. Install rear planetary gear. Install No. 2 one-way clutch in transaxle case with shiny side upward. Install one-way clutch on inner race while turning planetary gear clockwise. 8. Coat thrust washer with petroleum jelly and install on planetary gear. Check No. 2 one-way clutch operation by turning planetary gear. Gear should rotate freely in clockwise direction and lock in counterclockwise direction. Install snap ring. Ensure snap ring end is not aligned with cutout of transaxle case. 9. Install 2nd coast brake band guide with tip contacting transaxle case. Install 2nd brake flange with flat side facing upward. Install discs and plates in the following order: install disc, plate, disc, plate, disc, plate. 10. Install piston return spring assembly with springs over protrusions in transaxle case. Align groove of 2nd brake drum with guide. Install drum in transaxle case. Install snap ring. Using 2 hammers, compress piston return springs with handles. Install snap ring into groove. Ensure end gap of ring is not aligned with cutout in transaxle case. 11. Install 2nd brake drum gasket until gasket makes contact with 2nd brake drum. See Fig. 12 . Apply compressed air to center oil passage (next to manual valve lever shaft) and ensure piston movement. Align flukes of 2nd brake discs. Install hub on 2nd brake discs. Check distance between surfaces of 2nd brake hub and rear planetary gear. Distance should be about .20" (5.0 mm). 12. Install sun gear and input drum on No. 1 one-way clutch while turning sun gear clockwise. Ensure thrust washer is on sun gear input drum. Coat bearings and races "D" and "C" with petroleum jelly and install on ring gear and front planetary gear. See Fig. 45 . Install planetary gear on ring gear.

2001-02 AUTOMATIC TRANSMISSIONS A-131L Overhaul

13.

14.

15.

16.

Install front planetary gear assembly on sun gear. If planetary gear is correctly installed, ring gear flange bushing will be flush with or below intermediate shaft shoulder. Coat race with petroleum jelly and install on ring gear flange. Install intermediate shaft oil seal ring. Install 2nd coast brake band in transaxle case. Install pin through oil pump mounting bolt hole. Coat bearings and races "A" and "B" with petroleum jelly and install on both sides of forward clutch drum. See Fig. 45 . Coat clutch drum thrust washer with petroleum jelly and install with oil groove facing upward on direct clutch drum. Align flukes of direct clutch discs. Mesh hub with direct clutch flukes while turning clutch drum or forward clutch. If disc flukes are meshed with hub correctly, end of direct clutch drum bushing will be flush with surface of forward clutch. Place direct clutch and forward clutch into transaxle case. Rotate forward clutch to mesh front planetary ring gear and discs. Assembly is fully seated when distance is about .118" (3.00 mm) between direct clutch drum and sun gear input drum (shell). Coat race "A" with petroleum jelly and install on stator shaft. See Fig. 45 . Install "O" ring on oil pump. Install oil pump into transaxle case. Hold input shaft and lightly press oil pump body to slide oil seal rings on stator shaft through direct clutch drum. Install and tighten bolts to 16 ft. lbs. (22 N.m). NOTE: DO NOT apply excessive pressure on oil pump. If excessive pressure is used, seal rings will stick to direct clutch drum.

17. Measure input shaft end play. End play should be .012-.035" (.30-.90 mm). If end play is not as specified, replace oil pump race. Oil pump races are available in thicknesses of .031" (.80 mm) and .055" (1.40 mm). Ensure input shaft rotates smoothly. Install "O" rings on brake piston cover. Install outer spring, 2nd coast brake piston and cover into bore. Install snap ring. Ensure front end of piston rod contacts center of 2nd brake band depression. 18. Measure 2nd coast brake piston stroke by applying compressed air to oil passage in transaxle case. See Fig. 43 . Piston stroke should be .059-.118" (1.50-3.00 mm). If piston stroke is not within specification, replace piston rod. Piston rods are available in lengths of 2.811" (71.40 mm) and 2.870" (72.90 mm). Recheck piston travel after changing piston rod. It travel still exceeds specification, replace 2nd coast brake band. 19. Apply compressed air to oil passage and check piston rod movement. See Fig. 43 . Coat accumulator piston "O" rings with ATF. Install "O" rings on accumulator pistons. Check accumulator spring free length. See ACCUMULATOR SPRING SPECIFICATIONS . Replace as necessary. Install pistons and springs in appropriate locations. See Fig. 44 . Install accumulator cover and gasket. Tighten bolts to 89 INCH lbs. (10 N.m). 20. Install 2nd brake (governor) apply gasket and governor oil strainer. See Fig. 12 . Install throttle cable into transaxle case. Use care not to damage "O" ring. Ensure cable is fully seated in transaxle case. Install valve body assembly. Ensure kickdown switch wire is not under valve body assembly. Install valve body assembly bolts finger tight. Ensure bolts are installed correctly. See Fig. 11 . Tighten bolts to 89 INCH lbs. (10 N.m). 21. Align manual valve with pin on manual shift lever. Install manual valve body. Tighten bolts to 89 INCH lbs. (10 N.m). See Fig. 10 . Install detent spring on manual valve body. Tighten bolts to 89 INCH lbs. (10 N.m). Ensure manual valve lever is touching center of detent spring tip roller. 22. Install oil tubes. DO NOT bend or damage tubes. Install oil tube bracket. Tighten bolts to 89 INCH lbs. (10 N.m). Install oil strainer (filter). Tighten bolts to 89 INCH lbs. (10 N.m). Install magnets into oil pan. Ensure magnets do not interfere with oil tubes. Install oil pan with NEW gasket. See Fig. 9 . Tighten bolts to 43 INCH lbs. (4.9 N.m).

2001-02 AUTOMATIC TRANSMISSIONS A-131L Overhaul

23. Install governor body adapter, governor body with plate washer and thrust washer onto governor body. Install cover and "O" ring. Install cover bracket with 2 bolts. Tighten bolts to 115 INCH lbs. (13 N.m). Install throttle cable retaining plate. Install filler tube and dipstick. Install seal and park/neutral position switch. See Fig. 8 . Tighten and secure with nut stopper. Tighten nut to 61 INCH lbs. (6.9 N.m). 24. Adjust park/neutral position switch and tighten adjusting bolts to 48 INCH lbs. (5.4 N.m). Install manual shift lever. Tighten nut to 115 INCH lbs. (13 N.m). Install oil cooler pipes and unions. Tighten unions to 20 ft. lbs. (27 N.m). 25. Install torque converter on transaxle. Using a straightedge and calipers, measure torque converter installed depth. Distance should be more than .528" (13.40 mm) for Corolla or .906" (23.00 mm) for Prizm. See Fig. 46 .

Fig. 43: Checking 2nd Coast Brake Band Courtesy of TOYOTA MOTOR SALES, U.S.A. INC. ACCUMULATOR SPRING SPECIFICATIONS ACCUMULATOR SPRING SPECIFICATIONS (COROLLA - WITH AW A-131L) Application Color Length - In. (mm) Forward Clutch

2001-02 AUTOMATIC TRANSMISSIONS A-131L Overhaul

Inner Outer Direct Clutch 2nd Brake No. 1 No. 2

Brown Yellow/Green Blue/Red Yellow Yellow

1.523 (38.68) 2.074 (52.68) 2.935 (74.54) 1.385 (35.18) 2.231 (56.68)

ACCUMULATOR SPRING SPECIFICATIONS (PRIZM - WITH AW A-131L) Application Color Length - In. (mm) Forward Clutch Inner Red 1.890 (48.00) Outer Yellow/Green 3.193 (81.10) Direct Clutch Blue 2.935 (74.54) 2nd Brake No. 1 Yellow 1.385 (35.18) No. 2 Yellow 2.231 (56.68) ACCUMULATOR SPRING SPECIFICATIONS (COROLLA - WITH TOYOTA A-131L) Application Color Length - In. (mm) Forward Clutch Inner Brown 1.523 (38.68) Outer Yellow/Green 2.074 (52.68) Direct Clutch Yellow/Red 3.101 (78.76) 2nd Brake Green/Red 2.482 (63.05) ACCUMULATOR SPRING SPECIFICATIONS (PRIZM - WITH TOYOTA A-131L) Application Color Length - In. (mm) Forward Clutch Inner Red 1.890 (48.00) Outer Yellow 3.193 (81.10) Direct Clutch Yellow 2.842 (72.18) 2nd Brake Purple 2.625 (66.68)

2001-02 AUTOMATIC TRANSMISSIONS A-131L Overhaul

Fig. 44: Identifying Accumulator Piston & Spring Locations Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2001-02 AUTOMATIC TRANSMISSIONS A-131L Overhaul

Fig. 45: Identifying Thrust Bearing & Race Locations Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. BEARING RACE & THRUST BEARING SPECIFICATIONS Identification (1) Front Bearing Race A B&C D E Thrust Bearing A B&C D E Rear Bearing Race Outer Diameter - In. (mm) 1.693 (43.00) 1.492 (37.90) 1.772 (45.00) 1.469 (37.30) 1.654 (42.00) 1.421 (36.10) 1.772 (45.00) 1.480 (37.60)

2001-02 AUTOMATIC TRANSMISSIONS A-131L Overhaul

A B C D E (1) For bearing race and thrust bearing locations, refer to illustration. See Fig. 45 .

1.654 (42.00) 1.406 (35.70) 1.378 (35.00) N/A 1.480 (37.60)

Fig. 46: Measuring Torque Converter Depth Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS Application Bearing Retainer Bolt Converter-To-Drive Plate Bolt Corolla Prizm Counter-Driven Gear Lock Nut Standard Maximum Drive Plate Mounting Bolt Oil Cooler Union Nut Ft. Lbs. (N.m) 14 (19) 18 (25) 14 (19) 127 (172) 213 (289) 47 (64) 20 (27)

2001-02 AUTOMATIC TRANSMISSIONS A-131L Overhaul

Oil Pan Drain Plug Corolla Prizm Oil Pump Mounting Bolt Ring Gear Bolt Side Bearing Cap Bolt Transaxle-To-Engine Bolt 10-mm 12-mm Transaxle Rear Cover Bolt Accumulator Cover Bolt Detent Spring Bolt Governor Bracket Bolt Manual Shift Lever Nut Manual Valve Body Bolt Oil Pan Bolt Oil Pump Stator Shaft Bolt Oil Strainer Bolt Oil Tube Bracket Park/Neutral Position Switch Adjusting Bolt Retaining Nut Parking Lock Pawl Bracket Bolt Upper Valve Body-To-Lower Valve Body Bolt Valve Body Assembly-To-Transaxle Bolt

36 (49) 17 (23) 16 (22) 72 (97) 36 (49) 34 (46) 47 (64) 18 (25) INCH Lbs. (N.m) 89 (10) 89 (10) 115 (13) 115 (13) 89 (10) 43 (4.9) 89 (10) 89 (10) 89 (10) 48 (5.4) 61 (6.9) 65 (7.4) 48 (5.4) 89 (10)

TRANSAXLE SPECIFICATIONS
TRANSAXLE SPECIFICATIONS Application Bushing Inside Diameter (Maximum) Direct Clutch Oil Pump Body Ring Gear Flange Stator Shaft Front Rear Sun Gear Standard Maximum Converter Sleeve Runout Drive Plate Runout Input Shaft End Play In. (mm) 1.853 (47.07) 1.503 (38.18) .749-.750 (19.03-19.05) .849 (21.57) 1.066 (27.07) .867-.868 (22.03-22.05) .870 (22.10) .012 (.30) .008 (.20) .012-.035 (.30-.90)

2001-02 AUTOMATIC TRANSMISSIONS A-131L Overhaul

Intermediate Shaft End Play Intermediate Shaft Length Piston Stroke Direct Clutch Forward Clutch 2nd Coast Brake Planetary Pinion Gear Clearance Side Gear Backlash Torque Converter Depth Corolla Prizm CLUTCH DISC & PLATE QUANTITY Component Direct Clutch Forward Clutch Chevrolet Toyota 1st & Reverse Brake Aisin-Warner Toyota 2nd Brake

.019-.059 (.49-1.51) 4.560 (115.82) .054-.067 (1.37-1.70) .044-.058 (1.11-1.47) .059-.118 (1.50-3.00) .008-.020 (.20-.50) .002-.008 (.05-.20) .528 (13.40) .906 (23.00)

Disc 2 4 3 6 6 3

Plate 3 4 3 6 5 3

2001-02 AUTOMATIC TRANSMISSIONS A245E Overhaul

2001-02 AUTOMATIC TRANSMISSIONS A245E Overhaul

APPLICATION
CAUTION: Flush oil cooler and oil cooler lines prior to transaxle installation. Oil cooling system contamination may cause premature transaxle failure. TRANSAXLE APPLICATION Application Chevrolet Prizm (LSi) Toyota Corolla 1.8L (1) RPO code is MS7.

Transaxle Model A245E (1) A245E

IDENTIFICATION
TRANSAXLE Transaxles may be identified by using the Vehicle Identification Number (VIN). VIN locations are on top left corner of instrument panel or on driver's door post. See Fig. 1 . On Prizm, transaxle identification number is located on transaxle, above transaxle rear cover.

2001-02 AUTOMATIC TRANSMISSIONS A245E Overhaul

Fig. 1: Locating Vehicle Identification Number Plate & Certification Label Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. GEAR RATIOS TRANSAXLE GEAR RATIOS Gear Range 1st 2nd 3rd OD Reverse

Gear Ratio 3.643:1 2.008:1 1.296:1 0.892:1 2.977:1

DESCRIPTION & OPERATION

Transaxles have 4 forward speeds and reverse. Transaxle assemblies consists of a lock-up torque converter clutch, oil pump, valve body assembly, forward clutch, direct clutch, underdrive clutch, differential, 3 planetary gear sets and 3 one-way clutches. See Fig. 2 . The A245E transaxle shifting and torque converter clutch lock-up are controlled by an Engine Control Module (ECM) on Corolla or a Powertrain Control Module (PCM) on Prizm.

2001-02 AUTOMATIC TRANSMISSIONS A245E Overhaul

To minimize possibility of incorrect operation of vehicle transaxle, a shift lock mechanism is used. For more information, see appropriate SHIFT INTERLOCK SYSTEMS article.

Fig. 2: Identifying Transaxle Internal Component Locations Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

LUBRICATION

2001-02 AUTOMATIC TRANSMISSIONS A245E Overhaul

NOTE:

See appropriate SERVICING article.

TROUBLE SHOOTING
NOTE: Transmission malfunctions may be caused by poor engine performance, improper adjustments, fluid condition or failure of hydraulic, mechanical or electronic components. Ensure all concerns have been properly checked prior to transmission overhaul. See appropriate DIAGNOSIS article.

COMPONENT TESTS
TORQUE CONVERTER NOTE: Torque converter is a sealed unit and must be serviced as complete assembly. Perform following tests to check converter condition. Torque converter and oil cooler lines must be thoroughly cleaned and flushed if transaxle fluid is contaminated.

One-Way Clutch Test

1. Install turner and stopper of One-Way Clutch Tester (09350-32014) in torque converter. See Fig. 3 . Turner fits in inner race of one-way clutch. Stopper fits in notch of converter hub and outer race of one-way clutch. 2. Clutch should lock when rotated counterclockwise, and turn freely when rotated clockwise. If necessary, clean converter and retest clutch. Replace converter if clutch does not test as described.

Fig. 3: Checking Torque Converter One-Way Clutch

2001-02 AUTOMATIC TRANSMISSIONS A245E Overhaul

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Drive Plate Runout Test

Measure drive plate runout. See Fig. 4 . If runout exceeds .008" (.20 mm), or if ring gear is damaged, replace drive plate. If installing a new drive plate, note position of spacers. Tighten bolts to 47 ft. lbs. (64 N.m).
Converter Sleeve Runout Test

1. Temporarily mount torque converter to drive plate. Mount a dial indicator with needle resting on converter sleeve. See Fig. 5 . Rotate converter. If runout exceeds .012" (.30 mm), ensure converter is properly mounted to drive plate. 2. If converter is properly mounted and runout exceeds specification, replace torque converter. Mark position of converter on drive plate to ensure correct installation. Remove converter from drive plate.

Fig. 4: Checking Drive Plate Runout Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2001-02 AUTOMATIC TRANSMISSIONS A245E Overhaul

Fig. 5: Checking Converter Sleeve Runout Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

TRANSAXLE DISASSEMBLY
1. Remove oil cooler pipes, breather hose, manual shift lever and park/neutral position switch. Remove filler tube and dipstick. Remove throttle cable retaining bolt. Remove solenoid harness connector retaining bolt. 2. Remove oil pan and gasket. Remove magnet(s) from oil pan. Remove oil strainer (filter). See Fig. 6 . Remove manual detent spring. Disconnect solenoid connectors. Remove valve body assembly bolts. Note bolt length and location. See Fig. 7 . Remove throttle cable. Disconnect manual valve connecting rod. Remove valve body assembly. 3. Remove solenoid sub-harness from transaxle case. Remove check ball body and spring, next to 2nd brake accumulator. See Fig. 8 . Remove 2nd brake apply gasket. Remove 2nd brake drum seal. See Fig. 9 and Fig. 10 . 4. Apply 14 psi (1 kg/cm2 ) of compressed air to oil passage to remove underdrive clutch accumulator piston and spring. See Fig. 11 . Apply 14 psi (1 kg/cm2 ) of compressed air to oil passage at base of piston housing to remove forward clutch accumulator piston and springs. See Fig. 12 . Apply 14 psi (1 kg/cm2 ) of compressed air to oil passage to remove direct clutch accumulator piston and spring. See Fig. 13 .

2001-02 AUTOMATIC TRANSMISSIONS A245E Overhaul

5. Apply 14 psi (1 kg/cm2 ) of compressed air to oil passage to remove 2nd brake accumulator piston and spring. See Fig. 14 . NOTE: If manual shift linkage is damaged or needs to be disassembled, see MANUAL SHIFT LINKAGE under COMPONENT DISASSEMBLY & REASSEMBLY.

6. Remove transaxle housing bolts. Remove transaxle housing. Remove differential assembly. Remove oil tube bracket and tubes. Remove plate. Remove apply gasket. See Fig. 15 . Unbolt and remove oil pump assembly.

2001-02 AUTOMATIC TRANSMISSIONS A245E Overhaul

Fig. 6: Exploded View Of Transaxle Case Valve Body & Accumulators Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2001-02 AUTOMATIC TRANSMISSIONS A245E Overhaul

Fig. 7: Identifying Valve Body Assembly Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2001-02 AUTOMATIC TRANSMISSIONS A245E Overhaul

Fig. 8: Identifying Check Ball Location Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2001-02 AUTOMATIC TRANSMISSIONS A245E Overhaul

Fig. 9: Removing 2nd Brake Apply Gasket Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2001-02 AUTOMATIC TRANSMISSIONS A245E Overhaul

Fig. 10: Removing 2nd Brake Drum Seal Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2001-02 AUTOMATIC TRANSMISSIONS A245E Overhaul

Fig. 11: Removing Underdrive Clutch Accumulator Piston & Spring Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2001-02 AUTOMATIC TRANSMISSIONS A245E Overhaul

Fig. 12: Removing Forward Clutch Accumulator Piston & Spring Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2001-02 AUTOMATIC TRANSMISSIONS A245E Overhaul

Fig. 13: Removing Direct Clutch Accumulator Piston & Spring Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

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Fig. 14: Removing 2nd Brake Accumulator Piston & Spring Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2001-02 AUTOMATIC TRANSMISSIONS A245E Overhaul

Fig. 15: Removing & Installing Apply Gasket Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 7. Apply mark to 2nd coast brake servo apply piston rod where it meets case. Apply air 57-114 psi (4-8 kg/cm2 ) and measure piston rod travel (stroke). See Fig. 16 . Piston rod travel should be .059.138" (1.50-3.50 mm). If rod travel is not within specification, inspect band further during disassembly. Remove apply tube. See Fig. 17 . 8. Remove 2nd coast brake piston snap ring. Apply 14 psi (1 kg/cm2 ) of compressed air to oil passage to remove 2nd coast brake cover. Remove 2nd coast brake piston and spring. See Fig. 18 . 9. Remove direct clutch with forward clutch from transaxle case. Remove direct clutch from forward clutch. Remove thrust washer, bearings and races from forward clutch. See Fig. 19 . 10. Pull 2nd coast brake band pin and remove. Remove 2nd coast brake band. Remove front planetary ring gear. Remove race and bearing from ring gear. See Fig. 19 . 11. Remove front planetary gear. Remove bearings and races from both sides of planetary gear. Remove sun gear, sun gear input drum, thrust washer, 2nd brake hub and No. 1 one-way clutch. Using compressed air, confirm 2nd brake piston operates smoothly. See Fig. 20 . Remove 2nd coast brake band guide. 12. Remove 2nd brake drum retaining snap ring. Remove 2nd brake drum. Remove thrust washer and 2nd brake piston return spring. Remove plates, discs and flange. Note number and location of components for reassembly reference. Remove No. 2 one-way clutch retaining snap ring. Remove No. 2 one-way clutch and rear planetary gear. See Fig. 19 . 13. Remove thrust washers from both sides of planetary gear. Remove rear planetary ring gear with bearing and races. Using feeler gauge, measure 1st and reverse pack clearance. See Fig. 21 .

2001-02 AUTOMATIC TRANSMISSIONS A245E Overhaul

Clearance should be .047-.093" (1.19-2.35 mm). 14. Remove flange retaining snap ring. Remove flange, plates and discs. Note number and location of components for reassembly reference. Remove transaxle rear cover bolts. Tap rear cover using a plastic hammer. Remove cover. Using chisel, release staked area of intermediate shaft lock nut. 15. Secure counterdriven gear with appropriate holder. Remove intermediate shaft lock nut. See Fig. 22 . Remove intermediate shaft. Press out counterdrive gear. Using chisel, release staked area of countershaft lock nuts. Remove both lock nuts. See Fig. 23 .

Fig. 16: Checking 2nd Coast Brake Piston Stroke Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

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Fig. 17: Exploded View Of Transaxle Housing & Case Components Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2001-02 AUTOMATIC TRANSMISSIONS A245E Overhaul

Fig. 18: Removing 2nd Coast Brake Cover Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2001-02 AUTOMATIC TRANSMISSIONS A245E Overhaul

Fig. 19: Exploded View Of Transaxle Case Internal Components Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2001-02 AUTOMATIC TRANSMISSIONS A245E Overhaul

Fig. 20: Checking & Removing 2nd Brake Piston Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2001-02 AUTOMATIC TRANSMISSIONS A245E Overhaul

Fig. 21: Check 1st & Reverse Brake Clutch Pack Clearance Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2001-02 AUTOMATIC TRANSMISSIONS A245E Overhaul

Fig. 22: Removing Intermediate Shaft Lock Nut Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2001-02 AUTOMATIC TRANSMISSIONS A245E Overhaul

Fig. 23: Removing Countershaft Lock Nuts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 16. Using appropriate puller, remove counterdriven gear with thrust bearing. Remove countershaft assembly. Remove thrust bearing and race from countershaft. Remove underdrive clutch drum and anti-rattle clip. See Fig. 24 . Using compressed air, confirm underdrive brake piston operates smoothly. See Fig. 25 . Remove oil seal rings. Using appropriate press and adapter, carefully remove underdrive brake snap ring.

2001-02 AUTOMATIC TRANSMISSIONS A245E Overhaul

Fig. 24: Identifying Underdrive Clutch Drum Anti-Rattle Clip Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 17. Remove flange, plates and discs. Note number and location of components for reassembly reference. Remove piston return spring. Using compressed air, remove underdrive brake piston. See Fig. 25 . Using appropriate compressor, gradually compress 1st and reverse spring assembly and remove snap ring. See Fig. 26 . 18. Remove return spring assembly. Apply compressed air to oil passage in transaxle case and remove 1st and reverse brake piston. See Fig. 27 . If piston does not pop out, remove using needle-nose pliers. 19. Remove parking lock pawl stopper plate, torsion spring and spring guide. Remove pawl shaft clamp, shaft and lock pawl. Remove parking lock sleeve and cam guide bracket. See Fig. 17 . Remove underdrive brake accumulator piston cover and gasket. Remove accumulator piston and spring. 20. Using appropriate puller, remove bearing from transaxle housing. Remove 3 bolts and oil tube clamps inside transaxle housing. Remove 2 oil tubes. Remove bearing retainer bolt and retainer. Using appropriate puller, remove bearing from transaxle housing.

2001-02 AUTOMATIC TRANSMISSIONS A245E Overhaul

Fig. 25: Checking Underdrive Brake & Clutch Piston Operation Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2001-02 AUTOMATIC TRANSMISSIONS A245E Overhaul

Fig. 26: Compressing 1st & Reverse Brake Piston Return Springs Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

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Fig. 27: Checking & Removing 1st & Reverse Piston Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

COMPONENT DISASSEMBLY & REASSEMBLY

OIL PUMP
Disassembly

1. Remove race from stator shaft. Remove "O" ring and oil seal rings from oil pump body and stator shaft. Remove clutch drum thrust washer from stator shaft. 2. Mark stator shaft and oil pump body for reassembly reference. Remove stator shaft bolts. Separate stator shaft and oil pump body. Mark gear location for reassembly reference. Remove pump gears. Using screwdriver, remove front seal. See Fig. 28 .
Inspection

1. Note position of oil pump gears. Clean all parts with solvent. Dry parts using compressed air. Ensure oil passages are clear. Check driven gear-to-body clearance. Push driven gear against one side of oil pump. Measure clearance between driven gear and oil pump body. See Fig. 29 . Replace oil pump body if clearance is not within specification. See OIL PUMP CLEARANCE SPECIFICATIONS table. 2. Measure tip clearance between driven gear and crescent-shaped part of oil pump body. See Fig. 30 . Replace oil pump body if clearance is not within specification. See OIL PUMP CLEARANCE SPECIFICATIONS table. 3. Using feeler gauge and straightedge, measure side clearance of both gears. See Fig. 31 . Replace oil

2001-02 AUTOMATIC TRANSMISSIONS A245E Overhaul

pump body if clearance is not within specification. See OIL PUMP CLEARANCE SPECIFICATIONS table. 4. Using a dial indicator, measure inside diameter of oil pump body bushing. Maximum inside diameter should be 1.503" (38.18 mm). If inside diameter exceeds specification, replace oil pump body. 5. Measure inside diameter of stator shaft bushings. See Fig. 32 . Maximum front side bushing inside diameter should be .849" (21.57 mm). Maximum rear side bushing inside diameter should be 1.066" (27.07 mm). If inside diameter exceeds specification, replace stator shaft. OIL PUMP CLEARANCE SPECIFICATIONS Application Driven Gear-To-Pump Body Standard Maximum Gear-To-Crescent Standard Maximum Gear Side Clearance Standard Maximum
Reassembly

In. (mm) .0030-.0059 (.075-.149) .012 (.30) .0002-.0098 (.004-.248) .012 (.30) .0008-.0020 (.020-.050) .004 (.10)

1. Install NEW oil seal. Seal must be even with edge of oil pump body. Coat all components with ATF. Install pump gears aligning reference marks. Install stator shaft on pump body. Align bolt holes and tighten bolts to 89 INCH lbs. (10 N.m). 2. Coat thrust washer with petroleum jelly. Install thrust washer on oil pump body. Align washer tab with oil pump body. Install oil seal rings. Use care not to over expand rings. Using screwdrivers, check drive gear for smooth rotation. Install "O" ring. Install race on stator shaft. See Fig. 28 .

2001-02 AUTOMATIC TRANSMISSIONS A245E Overhaul

Fig. 28: Exploded View Of Oil Pump Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 29: Checking Oil Pump Driven Gear Clearance Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2001-02 AUTOMATIC TRANSMISSIONS A245E Overhaul

Fig. 30: Checking Oil Pump Gear Tip Clearance Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2001-02 AUTOMATIC TRANSMISSIONS A245E Overhaul

Fig. 31: Checking Oil Pump Gear Side Clearance Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

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Fig. 32: Measuring Stator Shaft Bushing Diameter Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. DIRECT CLUTCH
Disassembly

1. Remove snap ring from direct clutch drum. Remove flange, discs and plates. Note number and location of components for reassembly reference. See Fig. 33 . Using appropriate spring compressor, compress spring retainer and springs. Remove snap ring, clutch spring compressor, spring retainer and piston return springs. 2. Install direct clutch on oil pump. Apply compressed air to oil pump oval shaped oil passage to remove piston. See Fig. 34 . Remove direct clutch from oil pump. Remove clutch piston "O" rings.
Inspection

1. Clean all parts (except discs) with solvent. Dry parts using compressed air. Ensure check ball is free in piston. Apply low air pressure to small hole in piston to check for air leakage around piston valve. Inspect discs and plates for wear or burnt areas. If disc lining is peeled or discolored, replace discs as necessary. Replace all damaged components as necessary. NOTE: New discs must be soaked in ATF for 15 minutes prior to reassembly.

2. Measure inside diameter of direct clutch bushing. Inside diameter should be 1.900" (48.27 mm). If inside diameter exceeds specification, replace direct clutch.
Reassembly

2001-02 AUTOMATIC TRANSMISSIONS A245E Overhaul

1. Install NEW "O" rings on piston and coat with ATF. Using hand pressure, press direct clutch piston into clutch drum with cup side upward. Use care not to damage "O" rings. Install piston return springs, retainer and snap ring. Compress return springs and retainer using clutch spring compressor. 2. Ensure snap ring gap does not align with spring retainer claw. Install 3 plates and 3 discs in reverse order of removal. Install flange with flat side facing downward. Install snap ring. Ensure snap ring gap does not align with drum cutout. 3. Install direct clutch on oil pump. Using a dial indicator, measure direct clutch pack clearance. Apply compressed air to oil pump passage and note dial indicator reading. See Fig. 34 . Clutch pack clearance should be .019-.035" (.49-.89 mm). If clearance is not as specified, select appropriate flange to obtain correct piston stroke. Flanges are available in thicknesses of .102-.126" (2.60-3.20 mm) in .008" (.20 mm) increments.

Fig. 33: Exploded View Of Direct Clutch Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

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Fig. 34: Checking & Removing Direct Clutch Piston Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. FORWARD CLUTCH
Disassembly

2001-02 AUTOMATIC TRANSMISSIONS A245E Overhaul

1. Remove thrust washer. Remove thrust bearings and races from both sides of clutch. Remove clutch drum snap ring. Remove flange, discs and plates. Note number and location of components for reassembly reference. See Fig. 35 . Using appropriate spring compressor, compress spring retainer and return springs. 2. Remove snap ring. Remove spring compressor, spring retainer and return springs. To remove piston from clutch drum, apply compressed air to oil passage (hole nearest piston) on rear of forward clutch shaft. Remove "O" rings from piston. If necessary, remove oil seal rings.
Inspection

Clean all parts (except discs) with solvent. Dry parts using compressed air. Ensure check ball is free in piston. Apply low air pressure to small hole in piston to check for air leakage around piston valve. Inspect discs and plates for wear or burnt areas. If disc lining is peeled or discolored, replace discs as necessary. Replace all damaged components as necessary. NOTE:
Reassembly

New discs must be soaked in ATF for 15 minutes prior to reassembly.

1. Install NEW oil seal rings (if necessary). DO NOT over expand seal rings. Install NEW "O" rings on piston and coat with ATF. Using hand pressure, install piston in clutch drum with cup side upward. Use care not to damage "O" rings. Install piston return springs, retainer and snap ring. Compress return springs and retainer using clutch spring compressor. Install snap ring so ring gap does not align with spring retainer claw. 2. Install 4 plates and 4 discs in reverse order of removal. Install flange with flat side facing inward. Install snap ring. Ensure end gap of snap ring is not aligned with drum cutout. Position dial indicator on piston flange. Measure piston stroke by applying compressed air to oil passage (hole nearest piston) on rear of forward clutch shaft and note dial indicator reading. See Fig. 36 . 3. Piston stroke should be .056-.071" (1.42-1.81 mm). If piston stroke is not as specified, select appropriate flange to obtain correct piston stroke. 4. Flanges are available in thicknesses of .110-.142" (2.80-3.60 mm) in .008" (.20 mm) increments. Coat thrust washer, races and bearings with petroleum jelly and install components. See Fig. 35 .

2001-02 AUTOMATIC TRANSMISSIONS A245E Overhaul

Fig. 35: Exploded View Of Forward Clutch Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2001-02 AUTOMATIC TRANSMISSIONS A245E Overhaul

Fig. 36: Measuring Forward Clutch Piston Stroke Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. FRONT PLANETARY GEAR
Disassembly

1. Check No. 1 one-way clutch operation. Hold sun gear (shell) and turn hub. Hub should rotate freely clockwise and lock when turned counterclockwise. See Fig. 37 . Remove 2nd brake hub and No. 1 one-way clutch from sun gear. 2. Remove thrust washer from sun gear input drum. Remove snap ring. Remove sun gear input drum. Remove shaft snap ring from sun gear. Remove one-way clutch retainer if clutch requires replacement. Remove one-way clutch from hub. See Fig. 38 .
Inspection

1. Clean all parts with solvent. Dry parts using compressed air. Check thrust bearings, races and one-way clutch for wear or damage. Replace if necessary. 2. Measure inside diameter of sun gear flange bushing. Standard inside diameter should be .867.868" (22.03-22.05 mm). Maximum inside diameter is .870" (22.10 mm). If inside diameter exceeds specification, replace flange. 3. Measure planetary pinion gear thrust clearance. Standard clearance should be .008-.020" (.20-.50 mm). Maximum clearance is .020" (.50 mm). If clearance exceeds specification, replace planetary gear. See Fig. 39 .

2001-02 AUTOMATIC TRANSMISSIONS A245E Overhaul

4. Measure inside diameter of ring gear flange bushing. Standard inside diameter should be .749.750" (19.03-19.05 mm). If inside diameter exceeds specification, replace flange.
Reassembly

Install shaft snap ring to sun gear. Install sun gear to drum. Install snap ring to drum. Install thrust washer to sun gear input drum. See Fig. 38 . Rotate hub clockwise. Install one-way clutch and 2nd brake hub. Check one-way clutch operation. Hold sun gear and rotate hub. Hub should rotate freely clockwise and lock counterclockwise.

Fig. 37: Checking No. 1 One-Way Clutch Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

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Fig. 38: Exploded View Of Front Planetary Gear Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 39: Measuring Planetary Gear Thrust Clearance Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. REAR PLANETARY GEAR

2001-02 AUTOMATIC TRANSMISSIONS A245E Overhaul

Disassembly

1. Check No. 2 one-way clutch operation. Hold outer race and rotate hub. Hub should rotate freely counterclockwise and lock clockwise. See Fig. 40 . 2. Remove thrust washers from both sides of planetary gear. Separate No. 2 one-way clutch and planetary gear. Remove snap rings and side retainers from No. 2 one-way clutch. Note position of No. 2 one-way clutch and remove from outer race. See Fig. 41 .
Inspection

Clean all parts with solvent. Dry parts using compressed air. Check thrust washers and one-way clutch for wear or damage. Replace damaged parts as necessary. Measure planetary pinion gear thrust clearance. Standard clearance should be .008-.020" (.20-.50 mm). Maximum clearance is .020" (.50 mm). If clearance exceeds specification, replace planetary gear. See Fig. 39 .
Reassembly

1. Coat all parts with ATF. Install one-way clutch into outer race. Flanged side should face inward away from shiny side of outer race. See Fig. 40 . Install side retainers and snap rings. 2. Install planetary gear into one-way clutch. Planetary gear inner race should face inward from back side of outer race. Check operation of one-way clutch. See Fig. 40 . Coat thrust washers with petroleum jelly. Install thrust washers on both sides of gear, aligning thrust washer tab with hollow area in gear.

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Fig. 40: Installing & Checking No. 2 One-Way Clutch Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

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Fig. 41: Exploded View Of Rear Planetary Gear Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 1ST & REVERSE BRAKE PISTON
Disassembly

1. Using appropriate compressor, compress springs. See Fig. 42 . Remove spring retainer snap ring and compressor. 2. Remove piston return spring assembly. Apply compressed air to oil passage in transaxle case to remove piston. See Fig. 27 . Remove piston "O" rings.
Inspection

Clean all parts with solvent. Dry parts using compressed air. Inspect piston for roughness or damage. Replace as necessary.
Reassembly

1. Install NEW "O" rings on piston and coat with ATF. Install piston in transaxle case with spring seats facing upward. Position piston return spring assembly and snap ring in place. See Fig. 42 . 2. Using clutch spring compressor, compress piston return springs. Avoid bending spring retainer or damaging transaxle case by overtightening compressor. Push snap ring into place with fingers. 3. Ensure snap ring is fully seated and centered by spring retainer lugs. Ensure snap ring end gap is not aligned with cutouts. Remove spring compressor.

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Fig. 42: Exploded View Of 1st & Reverse Brake Piston Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 2ND COAST BRAKE
Disassembly

1. Prior to disassembly, check brake piston stroke. Apply paint to piston rod at point rod meets transaxle case. Apply compressed air to oil passage and measure piston stroke using appropriate wire gauge set. Piston stroke should be .059-.138" (1.50-3.50 mm). See Fig. 16 . 2. If piston stroke exceeds specification, check brake band. If brake band is serviceable but piston rod stroke is not within specification, select NEW piston rod. Piston rod is available in lengths of 2.811" (71.40 mm) and 2.870" (72.90 mm). 3. Remove oil seal from piston. Remove "E" ring while pushing piston with needle-nose pliers. Remove spring, washer and piston rod. See Fig. 43 .
Inspection

Replace brake band if lining is peeled or discolored or printed numbers are defaced. Before assembling NEW band, soak in ATF for 15 minutes.
Reassembly

Install washer and spring to piston rod. Install "E" ring. Install oil seal ring. DO NOT expand oil seal ring ends more than necessary for installation. See Fig. 43 .

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Fig. 43: Exploded View Of 2nd Coast Brake Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 2ND BRAKE PISTON
Disassembly & Reassembly

Apply compressed air to oil passage and remove 2nd brake piston. See Fig. 20 . Remove "O" rings from piston. Coat NEW "O" rings with ATF and install. Carefully press 2nd brake piston into 2nd brake drum. See Fig. 44 .

2001-02 AUTOMATIC TRANSMISSIONS A245E Overhaul

Fig. 44: Exploded View Of 2nd Brake Piston Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. COUNTERSHAFT ASSEMBLY
Disassembly

1. Remove planetary sun gear from countershaft. Remove snap ring from sun gear and countershaft assembly. Remove underdrive planetary gear, thrust bearing and race. See Fig. 45 . 2. Remove drive pinion with output flange, outer bearing, race and spacer. Note thickness and size of bearing race. Remove ring gear retaining snap ring. Remove ring gear from countershaft. 3. Remove remaining bearing from countershaft. Remove outer bearing race from drive pinion using a brass punch and hammer. Note size of bearing and bearing race.
Inspection

1. Clean all parts with solvent. Dry parts using compressed air. Inspect bearings, races, thrust bearing and race, drive pinion and gears for wear or damage. Replace components as necessary. 2. Measure inside diameter of planetary sun gear bushing. Standard diameter should be 1.1731.174" (29.80-29.83 mm). Maximum inside diameter is 1.176" (29.87 mm). If clearance exceeds specification, replace planetary sun gear. 3. Measure planetary pinion gear thrust clearance. Standard clearance should be .008-.020" (.20-.50 mm). See Fig. 39 . If clearance exceeds specification, replace planetary gear assembly.
Reassembly

1. Press bearing of thick inner race on countershaft. Install ring gear and snap ring to countershaft. Install bearing outer races to drive pinion. Press thick bearing race into flange side of drive pinion. Using adapters, press thin bearing race on remaining side of drive pinion. See Fig. 45 . 2. Install NEW spacer on countershaft. Install drive pinion on countershaft. Using bearing installer, install remaining countershaft bearing. Ensure clearance exists between output flange and bearing. Install inner race. 3. Temporarily install counterdriven gear on countershaft. Secure counterdriven gear. Install NEW lock

2001-02 AUTOMATIC TRANSMISSIONS A245E Overhaul

nut. DO NOT use old lock nut. Countershaft bearing preload must be checked. Tighten lock nut to 130-159 ft. lbs. (177-216 N.m). 4. Using Countershaft Adapter (09351-32170) and a spring scale, measure starting torque of countershaft. Before measuring starting torque, turn countershaft firmly to seat bearing. Starting torque should be 2.6-4.4 lbs. (1.2-2.0 kg). Replace spacer if starting torque exceeds specification. Recheck starting torque. See Fig. 46 . 5. Using a punch and hammer, stake lock nut. Remove counterdriven gear. Install thrust bearing and race "H". See Fig. 75 . Install underdrive planetary gear and snap ring. Install snap ring to sun gear. Install planetary sun gear to countershaft. See Fig. 45 .

Fig. 45: Exploded View Of Countershaft Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

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Fig. 46: Measuring Countershaft Torque Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. UNDERDRIVE CLUTCH & NO. 3 ONE-WAY CLUTCH
Disassembly

1. Remove one-way clutch and thrust washer from underdrive clutch drum. Remove snap ring from underdrive clutch drum. See Fig. 47 . Remove flange, discs and plates from clutch drum. Note number and location of components for reassembly reference. Using appropriate spring compressor, compress return spring plate. 2. Remove snap ring. Remove return spring and spring plate. Install oil seal rings to transaxle case (if necessary). Install underdrive clutch to transaxle case. Apply compressed air to oil passage in transaxle case to remove piston. See Fig. 25 . Remove "O" rings from piston.
Inspection

1. Clean all parts (except discs) with solvent. Dry parts using compressed air. Inspect discs and plates for wear or burnt areas. If discs are peeled or discolored, replace discs as necessary. 2. Ensure check ball is free in piston. Apply low air pressure to small hole in piston to check for air leakage around piston valve. Inspect discs and plates for wear or burnt areas. Replace all damaged components.

2001-02 AUTOMATIC TRANSMISSIONS A245E Overhaul

NOTE:

New discs must be soaked in ATF for 15 minutes prior to installation.

3. Measure inside diameter of underdrive clutch drum bushing. Standard diameter for front side of bushing should be 1.831-1.832" (46.50-46.53 mm). Standard diameter for rear side of bushing should be 2.165-2.167" (55.00-55.03 mm). Maximum inside diameter should be 1.833" (46.57 mm) for front side and 2.169" (55.08 mm) for rear side. Replace underdrive clutch drum if not within specification.
Reassembly

1. Coat "O" rings with ATF. Install "O" rings on piston. Carefully install underdrive clutch into clutch drum. Install spring plate and return spring to underdrive clutch. Compress return spring and install snap ring. 2. Ensure snap ring end does not align with spring retainer claw. Install 3 plates and 3 discs in reverse order of disassembly, ending with disc. Install flange with round end facing inward. Install snap ring. 3. Measure underdrive clutch piston stroke. Mount dial indicator so tip rests on underdrive clutch assembly. Apply air pressure to activate piston. See Fig. 25 . Piston stroke should be .059-.075" (1.501.90 mm). If piston stroke is not within specification, replace flange. 4. Flanges are available in thicknesses of .080" (2.04 mm), .087" (2.20), .094" (2.40 mm) and .098" (2.50 mm). Install appropriate flange to obtain correct clearance. 5. Install thrust washer on underdrive clutch drum. Install underdrive one-way clutch on underdrive clutch drum. Retainer claw must be facing upward. Check operation of one-way clutch. Hold clutch drum and rotate one-way clutch. One-way clutch should turn freely counterclockwise and lock clockwise. See Fig. 47 .

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Fig. 47: Exploded View Of Underdrive Clutch & No. 3 One-Way Clutch Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. UNDERDRIVE BRAKE & ACCUMULATOR
Disassembly

1. Compress return spring and remove snap ring. Remove plates, discs and flange. Note number and location of components for reassembly reference. Remove return spring. Remove oil seal rings (if

2001-02 AUTOMATIC TRANSMISSIONS A245E Overhaul

necessary). 2. Apply compressed air to oil passage in transaxle case to remove underdrive piston from transaxle case. See Fig. 25 . Remove "O" rings from piston. Remove oil gallery cover and gasket. Remove accumulator piston and spring from transaxle case. Remove "O" ring from piston. See Fig. 48 .
Inspection

1. Clean all parts (except discs) with solvent. Dry parts using compressed air. Inspect discs and plates for wear or burnt areas. If discs are peeled or discolored, replace discs as necessary. 2. Inspect underdrive brake piston. Ensure check ball is free by shaking piston. Ensure valve does not leak by applying low pressure compressed air to small hole in piston. NOTE:
Reassembly

New discs must be soaked in ATF for 15 minutes prior to reassembly.

1. Coat NEW "O" ring with ATF and install on accumulator piston. Install accumulator piston and spring. Install oil gallery gasket and cover. Tighten bolts to 89 INCH lbs. (10 N.m). Apply thread sealant to screws for oil gallery cover. Install screws and tighten to 65 INCH lbs. (7.4 N.m). 2. Install underdrive brake piston "O" rings. Coat "O" rings with ATF. Install piston in transaxle case with cupped side upward. Use care not to damage "O" rings. Install brake piston return spring. Install 3 plates and 3 discs. Install flange with flat end facing inward. 3. Using spring compressor, compress return spring. Install snap ring. Ensure snap ring end gap is not aligned with cutout. Using compressed air, ensure underdrive brake piston operates smoothly. See Fig. 25 .

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Fig. 48: Exploded View Of Underdrive Brake & Accumulator Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. VALVE BODY ASSEMBLY NOTE: All valve body assembly components must be installed in original location. Arrange components in sequence during removal for reassembly reference. Throttle pressure is changed according to number of adjusting rings. When assembling valve body, install same number of adjusting rings as were removed. Some valve bodies do not have adjusting rings. CAUTION: Note position of throttle valve adjusting screw before disassembly. Note which step at end of primary regulator valve sleeve contacts valve body prior to removal. Line pressure is affected by plunger location. See Fig. 49 .
Disassembly

Remove throttle cam. Remove solenoids. Remove pressure relief valve. Remove 19 bolts from lower valve

2001-02 AUTOMATIC TRANSMISSIONS A245E Overhaul

body. See Fig. 50 . Hold plate against lower valve body and carefully remove lower valve body. DO NOT lose check balls. Note location of check balls, retainers, pins and plugs in valve body. Remove plate and gasket. See Fig. 51 .

Fig. 49: Identifying Adjusting Screw & Plunger Sleeve Locations Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

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Fig. 50: Identifying Lower Valve Body Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

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Fig. 51: Exploded View Of Valve Body Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Inspection

1. Clean all parts with solvent. Dry parts with compressed air. When disassembling upper or lower valve body, maintain parts in order for reassembly reference. Ensure each valve is kept with corresponding spring. For upper and lower valve body exploded views, see Fig. 52 .

2001-02 AUTOMATIC TRANSMISSIONS A245E Overhaul

2. Ensure all valve body oil passages are clear. Inspect valves for scoring or roughness. Inspect valve springs for damage, squareness, rust and collapsed coils. Measure spring free length and outer diameter. 3. Replace spring if not within specification. See appropriate VALVE BODY SPRING SPECIFICATIONS table. Ensure valve body springs correspond with appropriate valve. Ensure check balls, pins, retainers, strainers and vibrating stopper are installed in appropriate locations. See Fig. 53 and Fig. 54 .

Fig. 52: Exploded View Of Upper & Lower Valve Bodies

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Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 53: Upper Valve Body Check Ball Locations Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2001-02 AUTOMATIC TRANSMISSIONS A245E Overhaul

Fig. 54: Locating Lower Valve Body Strainers Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. VALVE BODY SPRING SPECIFICATIONS (LOWER) Application Color Cooler By-Pass Valve None Pressure Relief Valve Red 2-3 Shift Valve Red 2nd Coast Modulator Valve White Cut-Back Valve None Primary Regulator Valve Red 1-2 Shift Valve Red Reverse Control Valve None Accumulator Control Valve Pink Low Coast Modulator Valve Blue VALVE BODY SPRING SPECIFICATIONS (UPPER) Application Color Secondary Regulator Valve None

Free Length - In. (mm) .965 (24.50) .709 (18.00) 1.004 (25.50) 1.268 (32.20) .740 (18.80) 1.638 (41.60) 1.004 (25.50) 1.008 (25.60) 1.154 (29.30) 1.122 (28.50)

Free Length - In. (mm) 1.449 (36.80)

2001-02 AUTOMATIC TRANSMISSIONS A245E Overhaul

Lock-Up Relay Valve 3-4 Shift Valve Downshift Plug Throttle Valve
Reassembly

None Red Yellow Red

.740 (18.80) 1.004 (25.50) 1.075 (27.30) .689 (17.50)

1. Coat all components with ATF. To reassemble, reverse disassembly procedure. Position NEW No. 2 gasket, plate and NEW No. 1 gasket on lower valve body. Ensure gaskets are installed in correct locations. See Fig. 55 . 2. Place lower valve body with plate and gaskets on upper valve body. DO NOT let components separate. Align each bolt hole in valve bodies with gaskets and plate. Turn assembly over and install lower valve body cover. 3. Install and finger tighten bolts in lower valve body to secure upper valve body. See Fig. 50 . Tighten valve body bolts to specifications. See TORQUE SPECIFICATIONS . Install NEW "O" rings on solenoids. Lubricate "O" rings with ATF and install solenoids. Tighten torque converter clutch solenoid bolt to 58 INCH lbs. (6.5 N.m). Tighten No. 2 solenoid bolt to 89 INCH lbs. (10 N.m).

Fig. 55: Identifying Valve Body Gaskets Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. MANUAL SHIFT LINKAGE
Disassembly & Reassembly

Unstake manual valve shaft spacer and remove. Drive out roll pin. Remove retaining hitch pin. Slide out shaft and remove manual valve lever and washer. Replace shaft seal as needed. To reassemble, reverse disassembly procedure. See Fig. 6 . DIFFERENTIAL

2001-02 AUTOMATIC TRANSMISSIONS A245E Overhaul

Disassembly

1. Mark ring gear and differential case for reassembly reference. Remove ring gear bolts and lock tabs. Using brass hammer, tap ring gear from differential case. Remove bearings from differential case using appropriate bearing splitter and puller. Remove speedometer drive gear. 2. Use a dial indicator to check side gear backlash. Hold one pinion against differential case. Measure side gear backlash. See Fig. 56 . Backlash should be .002-.008" (.05-.20 mm). If backlash is not within specification, side gear thrust washers must be replaced. 3. Drive out pinion shaft lock pin from ring gear side. Remove pinion shaft, pinion gears, side gears, and thrust washers. See Fig. 57 . Remove oil seals from transaxle housing and transaxle case. Remove bearing outer races and shims from transaxle case and housing.
Inspection

Clean all parts with solvent. Dry parts using compressed air. Check bearings and gears for wear or damage. Replace parts as necessary.
Reassembly

1. Install bearing outer races and original shims in transaxle housing and case. Select thrust washers that will ensure correct side gear backlash. Thrust washers are available in .002" (.05 mm) increments, in thicknesses from .037-.047" (.95-1.20 mm). Install thrust washers and side gears in differential case. 2. If possible, install same size thrust washers on both sides. Install pinion gears and pinion shaft. Check gear backlash to ensure proper thrust washers are used. When backlash is correct, drive lock pin through differential case and into pinion shaft. Stake differential case to retain lock pin. 3. Press side bearing on differential case. Install speedometer drive gear on differential case. Install remaining side bearing on differential case. 4. Install differential in transaxle case. Install transaxle housing. Install bolts in correct locations and tighten bolts to 21 ft. lbs. (29 N.m). See Fig. 58 . Measure differential bearing preload, using Differential Preload Adapter (09564-32011) and an INCH-lb. torque wrench. See Fig. 59 . 5. Preload must be within specification. See DIFFERENTIAL PRELOAD SPECIFICATIONS table. If preload is incorrect, remove differential from transaxle case and replace adjusting shim under bearing. Adjusting shims are available in thicknesses of .079-.114" (2.00-2.90 mm) in .002" (.05 mm) increments. Preload will change approximately 2.6-3.5 INCH lbs. (.3-.4 N.m) with each shim thickness. 6. When correct preload is obtained, remove differential from transaxle case. Install ring gear on differential case. Clean ring gear and mounting surface. Heat ring gear to 212F (100C) in an oil bath. DO NOT heat ring gear to temperatures greater than 230F (110C). Align ring gear on differential case and install NEW bolts. Tighten bolts evenly in crisscross pattern to 72 ft. lbs. (97 N.m). 7. Stake locking tabs. Stake one tab flush with flat surface of nut. Stake 2nd tab against corner of nut on tightening side. Coat lip of oil seals with multipurpose grease. DIFFERENTIAL PRELOAD SPECIFICATIONS Application New Bearings Used Bearings

INCH Lbs. (N.m) 7.1-12.4 (.8-1.4) 3.5-6.2 (.4-.7)

2001-02 AUTOMATIC TRANSMISSIONS A245E Overhaul

Fig. 56: Measuring Differential Pinion Gear Backlash Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2001-02 AUTOMATIC TRANSMISSIONS A245E Overhaul

Fig. 57: Exploded View Of Differential Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2001-02 AUTOMATIC TRANSMISSIONS A245E Overhaul

Fig. 58: Installing Transaxle Housing Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 59: Measuring Differential Bearing Preload Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

TRANSAXLE REASSEMBLY

2001-02 AUTOMATIC TRANSMISSIONS A245E Overhaul

NOTE:

Coat all oil seal rings, discs, plates, rotating parts and sliding surfaces with ATF prior to reassembly. Use petroleum jelly to hold bearings and races in place. Discs should be soaked in ATF for at least 15 minutes prior to installation. For bearing race and thrust bearing specifications and location, see Fig. 75 .

NOTE:

1. Install oil tube apply cover and gasket (if equipped). Install oil tubes. Install oil tube clamps. Install underdrive brake accumulator piston and spring. See Fig. 17 . 2. Install oil gallery cover and gasket. Tighten bolts to 89 INCH lbs. (10 N.m). Apply thread sealant to screws for oil gallery cover. Install screws and tighten to 65 INCH lbs. (7.0 N.m). 3. Install cam guide bracket. Install parking lock rod in guide bracket. Install parking lock sleeve with raised portion up. Install stopper plate on raised portion of lock sleeve. Install guide sleeve and spring. Install parking lock pawl, pawl shaft and shaft clamp. See Fig. 17 . 4. Install NEW "O" rings on 1st and reverse brake piston. Lubricate "O" rings with ATF. Using appropriate compressor, press 1st and reverse brake piston into transaxle case. 5. Install piston return spring and snap ring. Avoid bending spring retainer by overtightening bolt. See Fig. 26 . Ensure snap ring is fully seated and centered by 3 lugs on spring retainer. Ensure end gap of snap ring is not aligned with spring retainer claw. 6. Install underdrive brake piston "O" rings. Coat "O" rings with ATF. Install piston in transaxle case with cup side upward. Use care not to damage "O" rings. Install brake piston return spring. Install 3 plates and 3 discs. Start with plate and alternate with disc ending with disc. Install flange with flat end down. 7. Using appropriate compressor, compress return spring. Install snap ring. Ensure snap ring end gap is not aligned with cutout. Using compressed air, confirm underdrive brake piston moves smoothly. See Fig. 25 . Install oil seal rings to transaxle case. 8. Place counterdrive gear on press platform with NEW spacer installed. Place case on gear. Press bearing onto counterdrive shaft until seated. Install intermediate shaft. Install lock nut. Secure counterdrive gear from turning and tighten lock nut to 131 ft. lbs. (177 N.m). 9. Using INCH-lb. torque wrench, measure starting torque of intermediate shaft at counterdrive gear lock nut. See Fig. 60 . Starting torque for new bearings is 2.7-6.2 INCH lbs. (.3-.7 N.m). Starting torque for used bearings is 1.8-3.5 INCH lbs. (.2-.4 N.m).

2001-02 AUTOMATIC TRANSMISSIONS A245E Overhaul

Fig. 60: Measuring Drive Gear Turning Torque Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 10. If starting torque is less than specification, replace spacer and recheck. Stake lock nut in place. 11. Install underdrive one-way clutch assembly. Install anti-rattle clip. See Fig. 24 . Align clutch disc tabs in underdrive brake and install underdrive clutch assembly. Check operation of underdrive one-way clutch. Clutch should turn freely counterclockwise and lock clockwise. See Fig. 62 . 12. Measure clutch assembly height from sleeve to inner race. Height should be .681-.717" (17.29-18.21 mm). See Fig. 63 . Check underdrive clutch piston stroke. Position dial indicator stem on underdrive clutch assembly. See Fig. 64 . Apply compressed air to oil passage in transaxle case. See Fig. 25 . 13. Piston stroke should be .059-.075" (1.50-1.90 mm). If piston stroke is not within specification, install correct flange. Flanges are available in thicknesses of .080" (2.04 mm), .087" (2.20 mm), .094" (2.40 mm) and .098" (2.50 mm). Install thrust bearing "G". See Fig. 75 . Install sun gear in transaxle case. 14. Align clutch disc tabs in underdrive clutch. Install countershaft assembly. Check countershaft height. Measure distance from tip of countershaft to bolt seat of clutch support. See Fig. 65 . Countershaft height should be 1.193-1.280" (30.30-32.50 mm). 15. Install thrust bearing "F". See Fig. 75 . Press in counterdriven gear. Install NEW lock nut. Using holder and adapter, tighten lock nut to 133 ft. lbs. (180 N.m). Stake lock nut. Using a dial indicator, measure countershaft end play. See Fig. 61 . End play should be .008-.035" (.20-.89 mm).

2001-02 AUTOMATIC TRANSMISSIONS A245E Overhaul

Fig. 61: Checking Countershaft End Play Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 16. Apply gasket sealer to rear cover sealing areas. Install transaxle rear cover and bolts. Ensure bolts are installed in correct locations. See Fig. 66 . Tighten bolts to 89 INCH lbs. (10 N.m). Ensure intermediate shaft turns smoothly.

2001-02 AUTOMATIC TRANSMISSIONS A245E Overhaul

Fig. 62: Checking Underdrive Clutch Operation Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2001-02 AUTOMATIC TRANSMISSIONS A245E Overhaul

Fig. 63: Measuring Underdrive Clutch Assembly Height Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2001-02 AUTOMATIC TRANSMISSIONS A245E Overhaul

Fig. 64: Measuring Underdrive Clutch Piston Stroke Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2001-02 AUTOMATIC TRANSMISSIONS A245E Overhaul

Fig. 65: Measuring Height Of Countershaft Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2001-02 AUTOMATIC TRANSMISSIONS A245E Overhaul

Fig. 66: Identifying Transaxle Rear Cover Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 17. Install 1st and reverse brake components in transaxle case. Install 6 discs and 6 plates. Start with plate, alternate with disc, ending with disc. Install outer flange with flat area facing inward. Install snap ring in groove. Ensure end gap does not align with transaxle case cutout. 18. Check 1st and reverse brake clutch pack clearance. See Fig. 21 . Clearance should be .047.093" (1.19-2.35 mm). Install thrust bearing and races "A" in rear planetary ring gear. See Fig. 75 . Align disc tabs. Install thrust washer on rear planetary gear. Ensure tabs align with grooves of gear. 19. Align spline of planetary gear with tabs of 1st and reverse brake discs. Install rear planetary gear into 1st and reverse brake. Ensure inner surface of rear planetary gear is below upper surface of flange. See Fig. 68 . Install No. 2 one-way clutch with shiny side upward. Rotate planetary gear clockwise while installing No. 2 one-way clutch. 20. Check No. 2 one-way clutch operation. Planetary gear should rotate clockwise and lock counterclockwise. See Fig. 69 . Install thrust washer on planetary gear. Install snap ring. Ensure end gap of snap ring is not aligned with case cutouts. 21. Install 2nd brake flange with flat end facing upward. Install 3 discs and 3 plates, starting with disc, alternating with plate and ending with plate. Install piston return spring assembly with springs over case protrusions. Install 2nd brake band guide with tip contacting transaxle case. Align 2nd brake drum groove with bolt in transaxle case. 22. Install 2nd brake drum. Install snap ring in groove while compressing piston return springs with hammer handles. Ensure end gap of snap ring is not aligned with transaxle case cutouts. Install 2nd brake drum gasket in center oil passage until it contacts 2nd brake drum. Apply compressed air into 2nd brake oil passage in transaxle case. Ensure 2nd brake piston operates smoothly. See Fig. 20 . 23. Align 2nd brake disc tabs. Install No. 1 one-way clutch and 2nd brake hub. Check distance between surface of 2nd brake hub and rear planetary gear. See Fig. 70 . Distance should be approximately .20" (5.0 mm). Install thrust washer on sun gear input drum. Install sun gear and sun

2001-02 AUTOMATIC TRANSMISSIONS A245E Overhaul

24.

25.

26.

27.

28. 29.

30.

31.

gear input drum. Rotate sun gear clockwise while installing gear into one-way clutch. Install thrust bearing and race "B" on front planetary gear. See Fig. 75 . Install planetary gear. Install thrust bearing and race "C" on front planetary ring gear. See Fig. 75 . Install front planetary ring gear. Install intermediate shaft oil seal ring. If components installed in transaxle case are correctly installed, end of ring gear flange bushing will be even or slightly lower than intermediate shaft shoulder. See Fig. 71 . Install thrust bearing and races "D" on tip of ring gear flange. Install 2nd coast brake band into transaxle case. Install pin. Install thrust bearing and race "E" on forward clutch drum. See Fig. 75 . Install clutch drum thrust washer on direct clutch drum with oil groove facing upward. Align clutch disc tabs. Install direct clutch into forward clutch. If tabs are aligned with hub correctly, end of direct clutch drum bushing will be flush with surfaces of forward clutch. Rotate forward clutch to mesh with front planetary gear and discs. Install direct clutch and forward clutch into transaxle case. Check installation of direct/forward clutch assembly. Measure distance between direct clutch and sun gear drum (shell). See Fig. 72 . Distance should be .118" (3.0 mm). Install spring, 2nd coast brake piston and cover into bore. Install snap ring. Ensure front end of piston rod contacts center of 2nd brake band depression. Measure 2nd coast brake piston stroke by applying compressed air to oil passage in transaxle case. See Fig. 16 . Piston stroke should be .059-.138" (1.50-3.50 mm). Replace rod if stroke is not within specification. Rod lengths are available in lengths of 2.811" (71.40 mm) and 2.870" (72.90 mm). Install apply gasket in transaxle case. See Fig. 15 . Install differential. Install apply tube if removed. Apply gasket sealer (Three Bond 1281 or equivalent) to transaxle housing. Install transaxle housing. Install mounting bolts in original locations. Apply thread sealant to 1.38" (35 mm) bolt threads. See Fig. 58 . Tighten bolts to 21 ft. lbs. (29 N.m). Check differential side bearing preload. See DIFFERENTIAL under COMPONENT DISASSEMBLY & REASSEMBLY. Install race on stator shaft. Install "O" ring on oil pump. Install oil pump. Hold input shaft and lightly press oil pump body to slide oil seal rings on stator shaft through direct clutch drum. Install and tighten bolts to 18 ft. lbs. (25 N.m). NOTE: DO NOT apply excessive pressure on oil pump. Seal rings will stick to direct clutch drum if excessive pressure is used.

32. Ensure input shaft rotates smoothly. Using a dial indicator, measure input shaft end play. See Fig. 67 . End play should be .012-.035" (.30-.90 mm). Replace oil pump race if end play is incorrect. Oil pump races are available in thicknesses of .031" (.80 mm) and .055" (1.40 mm).

2001-02 AUTOMATIC TRANSMISSIONS A245E Overhaul

Fig. 67: Measuring Input Shaft End Play Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 33. Coat accumulator piston "O" rings with ATF. Install "O" rings on accumulator pistons. Measure spring free length and replace as necessary. See ACCUMULATOR SPRING SPECIFICATIONS (A245E) table. Install pistons and springs in transaxle case. See Fig. 73 . ACCUMULATOR SPRING SPECIFICATIONS (A245E) (1) Application Color Free Length - In. (mm) Direct Blue 2.768 (70.30) Clutch (C2) Forward Clutch (C1) Inner Red 1.437 (36.50) Spring Outer Red 2.480 (63.00) Spring Underdrive Clutch (C3) Inner Yellow 1.969 (50.00) Spring Outer White 2.815 (71.50) Spring

2001-02 AUTOMATIC TRANSMISSIONS A245E Overhaul

2nd Brake Brown 2.547 (64.70) (B2) (1) For accumulator spring locations, refer to illustration. See Fig. 73 . 34. Install 2nd brake apply gasket. See Fig. 9 . Install check ball body and spring in passage next to 2nd brake accumulator. See Fig. 8 . Install throttle cable. Use care not to damage "O" ring. Ensure cable is fully seated in transaxle case. Install solenoid wire(s) in transaxle case. 35. Hold valve body cam downward and install throttle cable in slot. Install manual valve connecting rod. Install valve body assembly. Ensure kickdown switch wire is not pinched under valve body assembly. Install valve body assembly. 36. Install valve body assembly bolts finger tight. Ensure proper length bolts are installed in correct location. See Fig. 7 . Tighten bolts to 89 INCH lbs. (10 N.m). Connect solenoid connector(s). 37. Install manual detent spring and cover. Install bolt and tighten bolt to 89 INCH lbs. (10 N.m). Ensure manual valve lever is in contact with center of roller at tip of detent spring. Install oil tubes. Install oil tube clamp and bracket. Tighten bolts to 89 INCH lbs. (10 N.m). Install oil strainer (filter) with NEW gasket. 38. Install magnet(s) in oil pan. Install NEW oil pan gasket and install oil pan. Tighten oil pan bolts to 46 INCH lbs. (5.2 N.m). Install throttle cable and solenoid lock plates. 39. Install oil cooler pipe unions (if necessary). Install park/neutral position switch to manual valve shaft. Install packing, nut, stopper and nut. Tighten nut to 106 INCH lbs. (12 N.m). Adjust park/neutral position switch (if necessary) and tighten adjusting bolts to 48 INCH lbs. (5.4 N.m). See appropriate SERVICING article. Stake nut to stopper. Install manual shift lever and tighten nut. Install filler tube and dipstick. Install oil cooler pipes. 40. Install torque converter on transaxle. Using a straightedge and calipers, measure torque converter installed depth. For torque converter depth specifications, see TORQUE CONVERTER DEPTH SPECIFICATIONS table. See Fig. 74 . TORQUE CONVERTER DEPTH SPECIFICATIONS Application In. (mm) Corolla .528 (13.40) Prizm .906 (23.00)

2001-02 AUTOMATIC TRANSMISSIONS A245E Overhaul

Fig. 68: Checking Rear Planetary Installation Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2001-02 AUTOMATIC TRANSMISSIONS A245E Overhaul

Fig. 69: Checking No. 2 One-Way Clutch Operation Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2001-02 AUTOMATIC TRANSMISSIONS A245E Overhaul

Fig. 70: Checking 2nd Brake Hub Installation Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2001-02 AUTOMATIC TRANSMISSIONS A245E Overhaul

Fig. 71: Checking Front Planetary Ring Gear Installation Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2001-02 AUTOMATIC TRANSMISSIONS A245E Overhaul

Fig. 72: Checking Direct/Forward Clutch Drum Assembly Installation Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2001-02 AUTOMATIC TRANSMISSIONS A245E Overhaul

Fig. 73: Identifying Accumulator Pistons & Springs Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 74: Measuring Torque Converter Depth Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2001-02 AUTOMATIC TRANSMISSIONS A245E Overhaul

Fig. 75: Identifying Bearing Race & Thrust Bearing Locations Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

TORQUE SPECIFICATIONS

2001-02 AUTOMATIC TRANSMISSIONS A245E Overhaul

TORQUE SPECIFICATIONS Application Bearing Retainer Bolt Converter-To-Drive Plate Bolt Corolla Prizm Countershaft Gear Lock Nut Drain Plug Drive Plate Bolt Corolla Prizm Oil Cooler Union Nut Oil Pump Bolt Ring Gear Bolt Transaxle Housing Bolt Accumulator Cover Bolt Apply Pipe Bracket Bolt Brake Band Guide Bolt Manual Detent Spring Bolt Oil Gallery Cover Bolt Oil Pan Bolt Corolla Prizm Oil Pump Stator Shaft Bolt Oil Strainer Bolt Oil Tube Clamp Bolt Park/Neutral Position Switch Adjusting Bolt Retaining Nut Parking Lock Pawl Bracket Bolt Parking Lock Pawl Spring Bolt Pressure Relief Valve Sensor Bracket Bolt Sensor Cover Bolt Solenoid Bolt Single Solenoid Other Solenoids Speed Sensor Bolt Transaxle Rear Cover Bolt Upper-To-Lower Valve Body Bolt Underdrive Brake Accumulator Bolt Screw

Ft. Lbs. (N.m) 13 (17) 18 (25) 14 (19) 131-159 (177-216) 13 (17) 47 (64) 61 (83) 22 (30) 18 (25) 72 (97) 21 (29) INCH Lbs. (N.m) 89 (10) 48 (5.4) 48 (5.4) 89 (10) 89 (10) 48 (5.4) 43 (4.9) 89 (10) 89 (10) 89 (10) 106 (12) 48 (5.4) 65 (7.4) 115 (13) 57 (6.4) 115 (13) 48 (5.4) 58 (6.5) 89 (10) 48 (5.4) 89 (10) 58 (6.5) 89 (10) 65 (7.4)

2001-02 AUTOMATIC TRANSMISSIONS A245E Overhaul

Valve Body-To-Transaxle Bolt

89 (10)

TRANSAXLE SPECIFICATIONS
TRANSAXLE SPECIFICATIONS Application Assembly Height (Underdrive Clutch) Bushing Inside Diameter Direct Clutch Oil Pump Body Planetary Sun Gear Standard Maximum Ring Gear Flange Stator Shaft Front Rear Sun Gear Flange Underdrive Clutch (Front) Standard Maximum Underdrive Clutch (Rear) Standard Maximum Countershaft End Play Countershaft Height Direct Clutch Pack Clearance Input Shaft End Play Piston Stroke Forward Clutch Underdrive Clutch 2nd Coast Brake Planetary Pinion Gear Thrust Clearance Side Gear Backlash Underdrive Brake Clutch Pack Clearance 1st & Reverse Brake Pack Clearance CLUTCH DISC & PLATE QUANTITY Application Direct Clutch Forward Clutch Underdrive Brake Underdrive Clutch In. (mm) .681-.717 (17.29-18.21) 1.900 (48.27) 1.503 (38.18) 1.173-1.174 (29.80-29.83) 1.176 (29.87) .749-.750 (19.03-19.05) .849 (21.57) 1.066 (27.07) .867-.868 (22.03-22.05) 1.831-1.832 (46.50-46.53) 1.833 (46.57) 2.165-2.167 (55.00-55.03) 2.169 (55.08) .008-.035 (.20-.89) 1.193-1.280 (30.30-32.50) .019-.035 (.49-.89) .012-.035 (.30-.90) .056-.071 (1.42-1.81) .059-.075 (1.50-1.90) .059-.138 (1.50-3.50) .008-.020 (.20-.50) .002-.008 (.05-.20) .042-.081 (1.07-2.05) .047-.094 (1.19-2.38)

Disc 3 4 3 3

Plate 3 4 3 3

2001-02 AUTOMATIC TRANSMISSIONS A245E Overhaul

1st & Reverse Brake 2nd Brake

6 3

6 3

THRUST BEARING & RACE SPECIFICATIONS (1) , (2) Application O.D. - In. (mm) "A" Front Race 1.646 (41.8) Bearing 1.728 (43.9) "B" Bearing 1.728 (43.9) "C" Bearing 2.283 (58.0) "D" Bearing 1.811 (46.0) Or 1.823 (46.3) Or 47.1 (1.854) "E" Bearing 1.654 (42.0) Rear Race 1.555 (39.5) "F" Bearing 1.496 (38.0) Rear Race 1.378 (35.0) "G" Bearing 1.772 (45.0) "H" Front Race 1.480 (37.6) Bearing 1.480 (37.6) (1) For bearing race and thrust bearing specifications and location, see Fig. 75 .
(2) O.D. = Outside Diameter; I.D. = Inside Diameter.

I.D. - In. (mm) 1.181 (30.0) 1.220 (31.0) 1.220 (31.0) 1.614 (41.0) 1.209 (30.7)

1.016 (25.8) 1.024 (26.0) .866 (22.0) .748 (19.0) 1.106 (28.1) .949 (24.1) .870 (22.1)

2002-03 AUTOMATIC TRANSMISSIONS Removal & Installation - Corolla & Matrix

2002-03 AUTOMATIC TRANSMISSIONS Removal & Installation - Corolla & Matrix

APPLICATION
TRANSAXLE APPLICATION Application Corolla Matrix (2003) 1.8L 1.8L 1.8L (4WD) Transaxle Model A245E U240E A246E U341F

REMOVAL & INSTALLATION

WARNING: Vehicles are equipped with Supplemental Inflatable Restraint (SIR) system. When servicing vehicles, use care to avoid accidental air bag deployment. SIR system-related components are located in various locations throughout interior and exterior of vehicles, depending on application. Do not use electrical test equipment on or near these circuits. If necessary, deactivate SIR system before servicing components. See appropriate AIR BAG DEACTIVATION PROCEDURES article in GENERAL INFORMATION. CAUTION: When battery is disconnected, vehicle computer and memory systems may lose memory data. Driveability problems may exist until computer systems have completed a relearn cycle. Before disconnecting battery, see appropriate COMPUTER RELEARN PROCEDURES article in GENERAL INFORMATION. COROLLA (A245E) & MATRIX (A246E)
Removal

NOTE:

To assist with removal & installation of transaxle, see Fig. 1 and Fig. 2 .

2002-03 AUTOMATIC TRANSMISSIONS Removal & Installation - Corolla & Matrix

Fig. 1: Exploded View Of A245E/A246E Underhood Removal Components Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002-03 AUTOMATIC TRANSMISSIONS Removal & Installation - Corolla & Matrix

Fig. 2: Exploded View Of A245E/A246E Undercar Removal Components Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 1. 2. 3. 4. 5. 6. Remove hood sub-assembly. Remove cylinder head cover No. 2. Remove battery. Remove the 4 bolts and battery carrier. Remove air cleaner assembly with hose. Remove floor shift cable transaxle control shift. Remove the nut from the control shaft lever. See Fig. 3 . Disconnect the control cable from the control shaft lever. Remove the clip and disconnect the control cable from the control cable bracket.

2002-03 AUTOMATIC TRANSMISSIONS Removal & Installation - Corolla & Matrix

7. Remove transaxle control cable support. Disconnect the wire harness clamp and control cable from the control cable support. See Fig. 4 . Remove the bolt and control cable support. 8. Remove transaxle control cable bracket No. 1. Remove the 2 bolts and control cable bracket. 9. Disconnect wire harness. Remove the 2 bolts and disconnect the 2 wire harnesses. See Fig. 5 . Remove the bolt and disconnect the wire harness clamp bracket. Remove the bolt and disconnect the wire harness clamp bracket.

Fig. 3: Locating Shift Cable Connection Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002-03 AUTOMATIC TRANSMISSIONS Removal & Installation - Corolla & Matrix

Fig. 4: Identifying Control Cable Support Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002-03 AUTOMATIC TRANSMISSIONS Removal & Installation - Corolla & Matrix

Fig. 5: Locating Wire Harness Connections Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 10. Disconnect the transaxle wire connector. Disconnect the park/neutral position switch connector. Disconnect the speedometer sensor connector (without ABS). 11. Remove transaxle oil filler tube sub-assembly. Remove the ATF lever gauge. Remove the 2 bolts, oil cooler tube clamp and oil filler tube. See Fig. 6 . Remove the "O" ring from the oil filler tube. 12. Disconnect oil cooler inlet tube No. 1. See Fig. 7 . Disconnect oil cooler outlet tube No. 1. 13. Disconnect oxygen sensor connector. Remove the foot rest. Pull up the floor carpet. Disconnect the oxygen sensor connector. 14. Suspend engine assembly. Disconnect the 2 PCV hoses. Install the No. 1 (12281-22021) and No. 2 (12281-15040) engine hangers in the correct direction. Tighten bolts to 28 ft. lbs. (38 N.m). Attach the engine chain hoist to the engine hangers. 15. Remove front wheels. 16. Remove engine under cover RH. 17. Remove engine under cover LH. 18. Drain automatic transaxle fluid. Remove the drain plug and gasket, and drain ATF. Install a new gasket and drain plug. 19. Remove exhaust pipe assembly front. 20. Remove front axle shaft assemblies. See appropriate AXLE SHAFTS article in DRIVELINE/AXLES. 21. Remove transaxle case protector. Remove the 2 bolts and case protector. 22. Remove starter assembly. Remove the nut and disconnect the starter wire. Disconnect the connector. Remove the 2 bolts and starter.

2002-03 AUTOMATIC TRANSMISSIONS Removal & Installation - Corolla & Matrix

23. Support transaxle assembly with a transaxle jack. 24. Remove transverse engine mounting insulator. Remove the 5 bolts, nut and engine mounting insulator LH. See Fig. 8 . 25. Remove transverse engine mounting bracket. Remove the 3 bolts and engine mounting bracket LH. 26. Remove transverse engine mounting insulator. Remove the bolt from the engine mounting bracket RR. Remove the 3 nuts, bolt and engine mounting insulator RR from the suspension member. 27. Remove transverse engine mounting insulator. Remove the bolt and nut from the engine mounting bracket FR. 28. Remove engine mounting member sub-assembly center. See Fig. 9 . Remove the 4 bolts, dynamic damper and member sub-assembly center with engine mounting insulator FR. 29. Remove transverse engine mounting bracket. Remove the 2 bolts and engine mounting bracket FR. 30. Remove transverse engine mounting bracket. Remove the 3 bolts and engine mounting bracket RR. 31. Remove flywheel housing under cover. 32. Remove transaxle assembly. Turn the crankshaft to gain access and remove the 6 torque converter bolts while holding the crankshaft pulley bolt with a wrench. See Fig. 10 . Remove the 6 engine-totransaxle bolts. See Fig. 11 . Separate and remove the transaxle. 33. Remove torque converter clutch assembly.

Fig. 6: Removing/Installing Oil Filler Tube Sub-Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002-03 AUTOMATIC TRANSMISSIONS Removal & Installation - Corolla & Matrix

Fig. 7: Removing/Installing Oil Cooler Inlet Tube No. 1 Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002-03 AUTOMATIC TRANSMISSIONS Removal & Installation - Corolla & Matrix

Fig. 8: Identifying Engine Mounting Bracket LH Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002-03 AUTOMATIC TRANSMISSIONS Removal & Installation - Corolla & Matrix

Fig. 9: Identifying Engine Mounting Member Sub-Assembly Center Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 10: Accessing Torque Converter Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002-03 AUTOMATIC TRANSMISSIONS Removal & Installation - Corolla & Matrix

Fig. 11: Identifying Transaxle-To-Engine Bolt Location Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Installation

1. Install the torque converter clutch to the transaxle. Using vernier calipers, measure the dimension "A", the transaxle fitting part and the converter fitting part of the drive plate. See Fig. 12 . 2. Using vernier calipers and a straight edge, measure the dimension "B" and check that "B" is greater than dimension "A". See Fig. 13 . Standard: "A" + 1 mm or more. Do not add the thickness of straight edge. 3. Install transaxle assembly. Install the transaxle and 6 bolts to the engine. See Fig. 11 . Tighten bolts to specification. See TORQUE SPECIFICATIONS . Install the 6 torque converter mounting bolts. First install yellowish green colored bolt and then the 5 remaining bolts. 4. Install flywheel housing under cover. 5. Install the engine mounting bracket RR and 3 bolts to the transaxle. 6. Install the engine mounting bracket FR and 2 bolts to the transaxle. 7. Install engine mounting member sub-assembly center. Install the dynamic damper, member subassembly center with engine mounting insulator FR and 4 bolts. See Fig. 9 . Tighten bolts to specification. See TORQUE SPECIFICATIONS . 8. Install the engine mounting insulator RR and bolt to the engine mounting bracket RR. Tighten the 3 nuts and bolt.

2002-03 AUTOMATIC TRANSMISSIONS Removal & Installation - Corolla & Matrix

9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20.

21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34.

Install the engine mounting bracket LH and 3 bolts to the automatic transaxle. Install the engine mounting insulator LH. 5 bolts and nut. See Fig. 8 . Install the bolt and nut to the engine mounting bracket FR. Install the starter and 2 bolts. Tighten bolts to specification. See TORQUE SPECIFICATIONS . Connect the connector. Install the starter wire and nut. Install transaxle case protector. Install the case protector with the 2 bolts. Install front axle shaft assemblies. See appropriate AXLE SHAFTS article in DRIVELINE/AXLES. Install exhaust pipe assembly front. Install engine under cover LH. See Fig. 2 . Install engine under cover RH. Install front wheels. Install oxygen sensor connector. Connect the oxygen sensor connector. Install the floor carpet and foot rest. Install transaxle oil filler tube sub-assembly. Temporarily install the oil cooler outlet tube No. 1. Temporarily install the oil cooler inlet tube No. 1. Coat a new "O" rings with ATF, and install them to the oil filler tube. Install the oil filler tube to the transaxle. See Fig. 6 . Install the oil cooler tube clamp and 2 bolts. Install the ATF lever gauge. Install oil cooler inlet tube No. 1. Tighten the oil cooler inlet tube No. 1. See Fig. 7 . Tighten bolts to specification. See TORQUE SPECIFICATIONS . Install oil cooler outlet tube No. 1. Tighten the oil cooler outlet tube No. 1. Connect the transaxle wire connector. Connect the park/neutral position switch connector. Connect the speedometer sensor connector (without ABS). Install wire harness. Install the wire harness clamp bracket and bolt. Install the wire harness clamp bracket and 2 wire harnesses with the 3 bolts. See Fig. 5 . Install transaxle control cable bracket No. 1. Install the control cable bracket and 2 bolts. Install the control cable support and bolt. See Fig. 4 . Connect the control cable and wire harness to the control cable support. Install floor shift cable transaxle control shift. Temporarily install the control cable to the control shaft lever with the nut. Install the control cable and clip to the bracket. See Fig. 3 . Install battery carrier. Install the battery carrier and 4 bolts. Tighten bolts to specification. See TORQUE SPECIFICATIONS . Install air cleaner assembly with hose. Install cylinder head cover No. 2. See Fig. 1 . Install hood sub-assembly. Inspect and adjust as necessary. Add and inspect automatic transaxle fluid. Adjust shift lever position. See appropriate SERVICING article. Inspect front wheel alignment. See appropriate SPECIFICATIONS & PROCEDURES article in WHEEL ALIGNMENT under SUSPENSION.

2002-03 AUTOMATIC TRANSMISSIONS Removal & Installation - Corolla & Matrix

Fig. 12: Measuring Drive Plate Depth (Dimension "A") Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002-03 AUTOMATIC TRANSMISSIONS Removal & Installation - Corolla & Matrix

Fig. 13: Measuring Torque Converter Installed Depth (Dimension "B") Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. MATRIX (U240E)
Removal

NOTE:

To assist with removal and installation of transaxle, see Fig. 14 and Fig. 15 .

2002-03 AUTOMATIC TRANSMISSIONS Removal & Installation - Corolla & Matrix

Fig. 14: Exploded View Of A240 Underhood Removal Components Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002-03 AUTOMATIC TRANSMISSIONS Removal & Installation - Corolla & Matrix

Fig. 15: Exploded View Of A240E Undercar Removal Components Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. Remove hood sub-assembly. Remove cylinder head cover No. 2. Remove battery. Remove the 4 bolts and battery carrier. Remove air cleaner assembly with hose. Disconnect floor shift cable transaxle control shift. Remove the nut from the control shaft lever. Disconnect the control cable from the control shaft lever. Push the claw of the clip and disconnect the control cable from the bracket. See Fig. 16 . Remove the clip from the bracket. 7. Remove transaxle control cable support. Disconnect the control cable from the control cable support. 1. 2. 3. 4. 5. 6.

2002-03 AUTOMATIC TRANSMISSIONS Removal & Installation - Corolla & Matrix

8. 9. 10. 11. 12. 13. 14. 15.

16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33.

34.

Remove the bolt and control cable support. See Fig. 17 . Remove transaxle control cable bracket No. 1. Remove the 2 bolts and control cable bracket. Disconnect wire harness. Remove the bolt and disconnect the wire harness. Remove the 2 bolts and disconnect the 2 wire harness clamp brackets. See Fig. 18 . Disconnect the transaxle wire connector. Disconnect the park/neutral position switch connector. Disconnect the 2 transaxle revolution sensor connectors. Remove transaxle oil filler tube sub-assembly. Remove the ATF lever gauge. Remove the bolt and oil filler tube. See Fig. 19 . Remove the "O" rings from the oil filler tube. Remove oil cooler inlet tube No. 1. Remove the 2 bolts and oil tube clamp. Disconnect the oil cooler inlet tube No. 1. See Fig. 7 . Remove oil cooler outlet tube No. 1. Disconnect the oil cooler outlet tube No. 1. Disconnect oxygen sensor connector. Remove the foot rest. Pull up the floor carpet. Disconnect the oxygen sensor connector. Suspend engine assembly. Disconnect the 2 PCV hoses. Install the No. 1 (12281-88600) and No. 2 (12282-88600) engine hangers in the correct direction. Attach the engine chain hoist to the engine hangers. Remove front wheels. Remove engine under cover RH. Remove engine under cover LH. Drain automatic transaxle fluid. Remove the drain plug and gasket, and drain ATF. Install a new gasket and drain plug. Remove floor panel brace front. Remove exhaust pipe assembly front. Remove front axle shaft assemblies, RH and LH. See appropriate AXLE SHAFTS article in DRIVELINE/AXLES. Remove starter assembly. Remove the nut and disconnect the starter wire. Disconnect the connector. Remove the 2 bolts and starter. Support the automatic transaxle with a transaxle jack. Remove the 5 bolts, nut and engine mounting insulator LH. See Fig. 20 . Remove the 3 bolts and engine mounting bracket LH. Remove the bolt from the engine mounting bracket RR. Remove the 3 nuts, bolt and engine mounting insulator RR from the suspension member. Remove the bolt and nut from the engine mounting bracket FR. Remove the 4 bolts and member sub-assembly center with engine mounting insulator FR. See Fig. 21 . Remove the 2 bolts and engine mounting bracket FR. Remove the 3 bolts and engine mounting bracket RR. Remove flywheel housing under cover. Remove transaxle assembly. Turn the crankshaft to gain access and remove the 6 bolts from torque converter while holding the crankshaft pulley bolt with a wrench. See Fig. 10 . Remove the 6 transaxle-to-engine bolts. See Fig. 22 . Separate and remove the automatic transaxle. Remove torque converter clutch assembly.

2002-03 AUTOMATIC TRANSMISSIONS Removal & Installation - Corolla & Matrix

Fig. 16: Disconnecting Floor Shift Cable Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002-03 AUTOMATIC TRANSMISSIONS Removal & Installation - Corolla & Matrix

Fig. 17: Locating Control Cable Support Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002-03 AUTOMATIC TRANSMISSIONS Removal & Installation - Corolla & Matrix

Fig. 18: Identifying Wire Harness Clamp Brackets Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 19: Locating Oil Filler Tube Bracket Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002-03 AUTOMATIC TRANSMISSIONS Removal & Installation - Corolla & Matrix

Fig. 20: Identifying Engine Mounting Insulator LH Bolt Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002-03 AUTOMATIC TRANSMISSIONS Removal & Installation - Corolla & Matrix

Fig. 21: Identifying Engine Mounting Member Sub-Assembly Center Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 22: Identifying Engine-To-Transaxle Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Installation

1. Install the torque converter clutch to the transaxle. Using vernier calipers, measure the dimension "A" the transaxle fitting part and the converter fitting part of the drive plate. See Fig. 12 . 2. Using vernier calipers and a straight edge, measure the dimension "B" and check that "B" is greater than dimension "A". See Fig. 13 . Standard: "A" + 1 mm or more. Do not add the thickness of straight edge. 3. Install transaxle assembly. Install the transaxle and 6 bolts to the engine. See Fig. 22 . Install the 6 torque converter mounting bolts. See Fig. 10 . Tighten bolts to specification. See TORQUE SPECIFICATIONS . 4. Install flywheel housing under cover. 5. Install the engine mounting bracket RR and 3 bolts to the transaxle. 6. Install the engine mounting bracket FR and 2 bolts to the transaxle.

2002-03 AUTOMATIC TRANSMISSIONS Removal & Installation - Corolla & Matrix

7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18.

19.

20. 21. 22. 23. 24. 25.

26. 27. 28. 29. 30. 31. 32.

Install the member sub-assembly center with engine mounting insulator FR and 4 bolts. See Fig. 21 . Install the engine mounting insulator RR and bolt to the engine mounting bracket RR. Install the engine mounting bracket LH and 3 bolts to the transaxle. Install the engine mounting insulator LH, 5 bolts and nut. See Fig. 20 . Install the bolt and nut to the engine mounting bracket FR. Install the starter and 2 bolts. Connect the connector. Install the starter wire and nut. Install front axle shaft assemblies, LH and RH. See appropriate AXLE SHAFTS article in DRIVELINE/AXLES. Install exhaust pipe assembly front. Install engine under covers, LH and RH. Install front wheels. Install oxygen sensor connector. Connect the oxygen sensor connector. Install the floor carpet and foot rest. Install transaxle oil filler tube sub-assembly. Coat a new "O" rings with ATF, and install them to the oil filler tube. Install the oil filler tube and bolt to the automatic transaxle. See Fig. 19 . Install the ATF lever gauge. Install oil cooler outlet tube No. 1. Temporarily install the oil cooler outlet tube No. 1. Temporarily install the oil cooler inlet tube No. 1. Install the oil cooler tube clamp and 2 bolts. Tighten the oil cooler outlet tube No. 1. Install oil cooler inlet tube No. 1. Tighten the oil cooler inlet tube No. 1. See Fig. 7 . Connect the transaxle wire connector. Connect the park/neutral position switch connector. Connect the 2 transaxle revolution sensor connector. Install wire harness. Install the wire harness with the bolt. Install the 2 wire harness clamp brackets with the 2 bolts. See Fig. 18 . Install the control cable bracket and 2 bolts. Install transaxle control cable support. Install the control cable support and bolt. See Fig. 17 . Connect the control cable and wire harness to the control cable support. Install floor shift cable transaxle control shift. Temporarily install the control cable to the control shaft lever with the nut. Install a new clip to the bracket. Connect the control cable to the bracket. See Fig. 16 . Insert the cable securely. Install the battery carrier and 4 bolts. Install air cleaner assembly with hose. Install cylinder head cover No. 2. Install and adjust hood sub-assembly. Add and inspect automatic transaxle fluid. Inspect and adjust shift lever position. See appropriate SERVICING article. Inspect front wheel alignment. See appropriate SPECIFICATIONS & PROCEDURES article in WHEEL ALIGNMENT under SUSPENSION.

MATRIX (U341F)
Removal

NOTE:

To assist with removal and installation of transaxle, see Fig. 23 .

2002-03 AUTOMATIC TRANSMISSIONS Removal & Installation - Corolla & Matrix

Fig. 23: Exploded View Of A240 Underhood Removal Components Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 1. Remove engine assembly with transaxle. See appropriate MECHANICAL article in ENGINES. 2. Remove transfer assembly. See appropriate REMOVAL & INSTALLATION article in TRANSFER CASES. 3. Remove transaxle case protector. Remove the 2 bolts and case protector. 4. Remove front axle shaft assembly LH. See appropriate AXLE SHAFTS article in DRIVELINE/AXLES. 5. Remove the bolt and control cable support. See Fig. 24 . 6. Remove transaxle control cable bracket No. 1. Remove the 2 bolts and control cable bracket. 7. Disconnect wire harness. Remove the bolt and disconnect the wire harness clamp bracket. See Fig. 25 . Remove the 2 bolts and disconnect the 2 ground wire harnesses. See Fig. 26 .

2002-03 AUTOMATIC TRANSMISSIONS Removal & Installation - Corolla & Matrix

Fig. 24: Locating Control Cable Support Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002-03 AUTOMATIC TRANSMISSIONS Removal & Installation - Corolla & Matrix

Fig. 25: Identifying Wire Harness Clamp Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002-03 AUTOMATIC TRANSMISSIONS Removal & Installation - Corolla & Matrix

Fig. 26: Locating Ground Wire Connections Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 8. Disconnect the transaxle wire connector. Disconnect the park/neutral position switch connector. Disconnect the transaxle revolution sensor connector. 9. Remove transaxle oil filler tube sub-assembly. Remove the ATF lever gauge. Remove the 2 bolts, oil cooler tube clamp and oil filler tube. Remove the "O" ring from the oil filler tube. 10. Remove oil cooler inlet tube No. 1. See Fig. 7 . 11. Remove oil cooler outlet tube No. 1. 12. Remove the 3 bolts and engine mounting bracket LH from the automatic transaxle. 13. Remove the 2 bolts and engine mounting bracket FR from the automatic transaxle. 14. Remove flywheel housing under cover. 15. Remove automatic transaxle assembly. Turn the crankshaft to gain access and remove the 6 torque converter bolts while holding the crankshaft pulley bolt with a wrench. See Fig. 10 . Remove the 6 engine-to-transaxle bolts. See Fig. 27 . Remove the automatic transaxle from the engine. 16. Remove torque converter clutch assembly.

2002-03 AUTOMATIC TRANSMISSIONS Removal & Installation - Corolla & Matrix

Fig. 27: Identifying Engine-To-Torque Converter Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Installation

1. Install the torque converter clutch to the transaxle. Using vernier calipers, measure the dimension "A", the transaxle fitting part and the converter fitting part of the drive plate. See Fig. 12 . 2. Set the key of the front oil pump drive gear at the top and put a mark on the housing. Put a mark on the torque converter so that its groove can be clearly indicated. 3. Match the 2 marks on the case and the converter and fit the splined part of the input shaft to the spline part of the turbine runner. 4. Rotating the converter, fit the spline part of the stator shaft with the spline part of the stator. Rotate it about 180 degrees. NOTE: When rotating the converter, do not push it by excessive force.

5. Rotating the converter; match the 2 marks on the case and the converter again and fit the key of the oil pump drive gear into the key way of the converter. 6. Using vernier calipers and a straight edge, measure the dimension "B" and check that "B" is greater

2002-03 AUTOMATIC TRANSMISSIONS Removal & Installation - Corolla & Matrix

7. 8. 9. 10. 11.

12. 13. 14. 15. 16. 17.

18. 19. 20. 21.

than dimension "A". See Fig. 13 . Standard: "A" + 1 mm or more. Do not add the thickness of straight edge. Install the automatic transaxle to the engine with the 6 bolts. Install the 6 torque converter mounting bolts. First install yellowish green colored bolt and then the remaining 5 bolts. Install flywheel housing under cover. Install transverse engine mounting bracket. Install the mounting bracket FR to the transaxle with the 2 bolts. Install the mounting bracket LH to the automatic transaxle with the 3 bolts. Install transaxle oil filler tube sub-assembly. Temporarily install the oil cooler outlet tube No. 1. Temporarily install the oil cooler inlet tube No. 1. Coat a new "O" rings with ATF, and install them to the oil filler tube. Install the oil filler tube to the automatic transaxle. Install the oil cooler tube clamp and 2 bolts. Install the ATF lever gauge. Install oil cooler inlet tube No. 1. Tighten the oil cooler inlet tube No. 1. Install oil cooler outlet tube No. 1. Tighten the oil cooler outlet tube No. 1. Connect the transaxle wire connector. Connect the park/neutral position switch connector. Connect the transaxle revolution sensor connector. Install the wire harness clamp bracket and bolt. Install the 2 wire harness with the 2 bolts. Install transaxle control cable bracket No. 1. Install the control cable bracket with the 2 bolts. Install transaxle control cable support. Install the control cable support with the bolt. Connect the control able to the control cable support. Install front axle shaft assembly LH. See appropriate AXLE SHAFTS article in DRIVELINE/AXLES. Install automatic transaxle case protector (a) Install the case protector with the 2 bolts. Install transfer assembly. See appropriate REMOVAL & INSTALLATION article in TRANSFER CASES. Install assembly with transaxle. See appropriate MECHANICAL article in ENGINES.

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS (COROLLA WITH A245E & MATRIX WITH A246E) Application Ft. Lbs. (N.m) Mounting Insulator Bolt 64 (87) Mount Bracket LH Bolt/Nut Bolt "A" 38 (52) Bolt "B" & "C" 59 (80) Mount Crossmember Bolt/Nut Bolt "A" 29 (39) Bolt "B" 38 (52) Mount Insulator Bracket LH Bolt/Nut 38 (52) Oil Cooler Inlet & Outlet Tube No. 1 25 (35) Starter Bolt 29 (39) Torque Converter Bolt 20 (28) Transaxle Case Protector Bolt 14 (18) Transaxle Mount Assembly Bolt 47 (64)

2002-03 AUTOMATIC TRANSMISSIONS Removal & Installation - Corolla & Matrix

Transaxle Mount Assembly Brace Bolt Transaxle-To-Engine Block Bolt (1) "A" "B" "C" Wheel Lug Nut Air Cleaner Assembly Bolt Battery Carrier Bolt Control Cable Bracket No. 1 Bolt Cylinder Head Cover Bolt Hood Sub-Assembly Bolt Starter Wire Nut (1) See Fig. 11 . TORQUE SPECIFICATIONS (MATRIX WITH U240E) Application Mounting Bracket FR & RR Bolt Mount Bracket LH Bolt/Nut Bolt "A" Bolt "B" & Nut "B" Mount Insulator Bracket FR Bolt/Nut Mount Insulator RR Bolt Mount Member Center Bolt Bolt "A" Bolt "B" Oil Cooler Inlet & Outlet Tube No. 1 Starter Bolt Torque Converter Bolt Transaxle Case Protector Bolt Transaxle Mount Assembly Bolt Transaxle Mount Assembly Brace Bolt Transaxle-To-Engine Block Bolt (1) "A" "B" "C" Wheel Lug Nut Air Cleaner Assembly Bolt Battery Carrier Bolt Control Cable Bracket No. 1 Bolt Cylinder Head Cover No. 2 Bolt Hood Sub-Assembly Bolt

15 (20) 47 (64) 34 (46) 17 (23) 76 (103) INCH Lbs. (N.m) 62 (7) 115 (13) 106 (12) 62 (7) 115 (13) 115 (13)

Ft. Lbs. (N.m) 47 (64) 38 (52) 59 (80) 38 (52) 64 (87) 29 (39) 38 (52) 25 (35) 29 (39) 30 (41) 14 (18) 47 (64) 15 (20) 47 (64) 34 (46) 17 (23) 76 (103) INCH Lbs. (N.m) 62 (7) 89 (10) 106 (12) 62 (7) 115 (13)

2002-03 AUTOMATIC TRANSMISSIONS Removal & Installation - Corolla & Matrix

Shift Cable Nut Starter Wire Nut Wire Harness Bolt (1) See Fig. 22 . TORQUE SPECIFICATIONS (MATRIX WITH U341E) Application Mounting Bracket FR & RR Bolt Mount Bracket LH Bolt/Nut Bolt "A" Bolt "B" & Nut "B" Mounting Insulator RR Bolt Mount Insulator Bracket FR Bolt/Nut Mount Member Center Bolt Bolt "A" Bolt "B" Oil Cooler Inlet & Outlet Tube No. 1 Starter Bolt Torque Converter Bolt Transaxle Case Protector Bolt Transaxle Mount Assembly Bolt Transaxle Mount Assembly Brace Bolt Transaxle-To-Engine Block Bolt (1) "A" "B" "C" Wheel Lug Nut Air Cleaner Assembly Bolt Battery Carrier Bolt Control Cable Bracket No. 1 Bolt Cylinder Head Cover No. 2 Bolt Hood Sub-Assembly Bolt Shift Cable Nut Starter Wire Nut Wire Harness Bolt (1) See Fig. 27 .

80 (9) 115 (13) 89 (10)

Ft. Lbs. (N.m) 47 (64) 38 (52) 59 (80) 64 (87) 38 (52) 29 (39) 38 (52) 25 (35) 29 (39) 20 (28) 17 (23) 47 (64) 15 (20) 47 (64) 34 (46) 17 (23) 76 (103) INCH Lbs. (N.m) 62 (7) 89 (10) 106 (12) 62 (7) 115 (13) 80 (9) 115 (13) 89 (10)

2001-02 AUTOMATIC TRANSMISSIONS Servicing - Toyota

2001-02 AUTOMATIC TRANSMISSIONS Servicing - Toyota

APPLICATION
TRANSAXLE APPLICATION (CARS) Application Avalon Camry 2001 2.2L 3.0L 2002 2.4L 3.0L Camry Solara 2001 2.2L 3.0L 2002 2.4L 3.0L Celica 1.8L 1.8L Corolla 1.8L 1.8L ECHO Prius TRANSAXLE/TRANSMISSION APPLICATION (SUV, TRUCKS & VANS) Application Highlander 2.4L 2.4L 3.0L 3.0L Land Cruiser RAV4 2WD 4WD Sequoia Trans. Model A-541E

A-140E A-541E U-241E U-140E

A-140E A-541E U-241E A-541E U-240E U-341E A-131L A-245E U-340E P-111

Trans. Model U-140F U-241E U-140F U-140E

(1) A-343F

U-241E U-140F

2001-02 AUTOMATIC TRANSMISSIONS Servicing - Toyota

2WD 4WD Sienna Tacoma 2WD 2.4L 2.7L 3.4L 4WD 2.7L 3.4L Tundra 2WD 4WD 4Runner 2WD 4WD (1) Equipped with separate transmission oil cooler.

(1) A-340E (1) A-341F

A-541E

A-44D A-340E A-340E A-340F A-340F

(1) A-340E (1) A-340F

A-340E A-340F

IDENTIFICATION
OIL PAN GASKET

2001-02 AUTOMATIC TRANSMISSIONS Servicing - Toyota

Fig. 2: Identifying Oil Pan Gasket (A-131L & A-140E) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2001-02 AUTOMATIC TRANSMISSIONS Servicing - Toyota

Fig. 3: Identifying Oil Pan Gasket (A-245E) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2001-02 AUTOMATIC TRANSMISSIONS Servicing - Toyota

conditions, replace transmission fluid every 30,000 miles or 24 months. CHECKING FLUID LEVELS NOTE: When checking fluid level for the transmission, if vehicle has been operating in heavy traffic, towing a trailer or at high speeds in hot weather, wait 30 minutes before checking fluid level.

Transaxle/Transmission (Except Prius)

1. Drive vehicle until engine and transmission reach normal operating temperature. Park vehicle on level surface and apply parking brake. With engine idling and brakes applied, move gearshift lever through all positions ending in "P" position. 2. Check fluid level on transmission dipstick. Fluid level should be in HOT range marked on dipstick. Add proper type of fluid if necessary. See RECOMMENDED FLUIDS . DO NOT overfill.
Transaxle (Prius)

1. Drive vehicle until engine and transaxle reaches normal operating temperature. Park vehicle on level surface and apply parking brake. With engine idling and brakes applied, move gearshift lever through all positions ending in "P" position. 2. Raise and support vehicle. Carefully remove transaxle fill plug to check level. Fluid level should be within .2" (5 mm) of bottom of fill plug opening. See Fig. 9 . If fluid is low, fill with proper type fluid until fluid is level with fill plug opening. See RECOMMENDED FLUIDS . DO NOT overfill.

Fig. 9: Checking Transaxle Fluid level (Prius) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2001-02 AUTOMATIC TRANSMISSIONS Servicing - Toyota

RECOMMENDED FLUIDS DIFFERENTIAL FLUID TYPE Application All Models TRANSAXLE/TRANSMISSION FLUID TYPE Application Camry, Camry Solara, Celica, ECHO, Highlander, Prius & RAV4 (1) All Others (1) RAV4 EV uses Dexron-III ATF FLUID CAPACITIES TRANSAXLE/TRANSMISSION FLUID CAPACITIES (1) Application Avalon Camry 2001 A-140E A-541E 2002 U-140E U-241E Celica U-240E U-341E Corolla A-131L A-245E ECHO Highlander 2WD 4WD Land Cruiser Prius RAV4 U-241E U-140F Sequoia Sienna Solara 2001

Fluid Type SAE 75-90 APL GL-5 Gear Oil

Fluid Type Type T Or T-IV ATF Dexron-II Or Dexron-III ATF

Qts. (L) 5.0 (4.8)

2.6 (2.5) 5.0 (4.8) 3.7 (3.5) 4.1 (3.9) 4.3 (4.1) 3.1 (2.9) 2.6 (2.5) 3.3 (3.1) 3.1 (2.9) 3.5 (3.3) 4.1 (3.9) 2.1 (2.0) 4.9 (4.6) 3.5 (3.3) 4.1 (3.9) 2.1 (2.0) 5.0 (4.8)

2001-02 AUTOMATIC TRANSMISSIONS Servicing - Toyota

A-140E A-541E 2002 A-140E A-541E Tacoma 2WD (2.4L) 2WD (2.7L & 3.4L) 4WD Tundra & 4Runner 2WD 4WD (1) Approximate capacity is listed. DRAINING & REFILLING

2.6 (2.5) 5.0 (4.8) 2.6 (2.5) 5.0 (4.8) 2.5 (2.4) 1.7 (1.6) 2.1 (2.0) 1.7 (1.6) 2.1 (2.0)

CAUTION: A large amount of material debris including steel (magnetic) and nonmagnetic (brass, aluminum or clutch fiber particles) may indicate excessive transmission wear or damage. Check the magnet in the oil pan for steel particles which indicate bearing, plate or hardware damage. CAUTION: When working with FIPG sealing material, you must observe the following: Using a razor blade and gasket scraper, remove all FIPG sealing material from the gasket surfaces. Thoroughly clean all components to remove all loose material. Clean both sealing surfaces with a non-residue solvent. Apply FIPG in an approximately 0.04" (1 mm) wide bead along the sealing surface. Parts must be assembled within 10 minutes of application. Otherwise, the FIPG sealing material must be removed and reapplied. NOTE: Always warm transmission/transaxle to operating temperature of 158-176F (70-80C) prior to draining and refilling. When removing transmission/transaxle oil pan and filter, note bolt size and length for reassembly reference.

NOTE:

A-131L & A-140E (Camry, Camry Solara & Corolla)

1. Raise and support vehicle. Remove drain plug and drain transmission fluid into proper container. Remove the bolts and the transmission oil pan and gasket. Carefully remove oil pan. Inspect for excess debris in bottom of oil pan. 2. Remove bolts, transmission fluid filter and gasket. See Fig. 10 . Clean oil pan. 3. Install the magnets in the oil pan. Replace the fluid filter and install a NEW oil pan gasket. Install and tighten the oil pan and drain plug to specification. See TORQUE SPECIFICATIONS . Fill with appropriate fluid and check for proper level. See CHECKING FLUID LEVEL .

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Fig. 10: Removing & Installing Fluid Filter & Pipe Bracket (A-131L) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
A-245E (Corolla)

1. Raise and support vehicle. Remove left side engine undercover. Remove drain plug and drain ATF. Remove oil pan and gasket. Remove the 18 bolts. Discard the gasket. Remove the 3 bolts, fluid filter and gasket. Clean gasket surfaces, being careful not to damage sealing surfaces. 2. Install a NEW gasket on fluid filter. Install fluid filter and gasket with the 3 bolts. See Fig. 11 . Install the 2 magnets in oil pan. Install a NEW gasket on the oil pan and install them on the transaxle. Install the 18 bolts and drain plug. Tighten to specification. See TORQUE SPECIFICATIONS . Install left side engine undercover. Fill with proper ATF and check fluid level. See CHECKING FLUID LEVEL .

2001-02 AUTOMATIC TRANSMISSIONS Servicing - Toyota

Fig. 11: Removing & Installing Fluid Filter & Gasket (A-245E) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
A-340E & A-340F (Sequoia, Tacoma, Tundra & 4Runner)

1. Raise and support vehicle. Remove drain plug to drain fluid. To remove oil pan, remove all 19 bolts, and install gasket cutter in space between pan and transmission body. Using gasket cutter, carefully cut old sealer around entire surface of pan. See Fig. 12 . Remove fluid filter and gaskets. 2. Clean transmission oil pan. Remove and clean the magnets in the pan of all metal particles. Install fluid filter and gaskets. See Fig. 13 . Install a bead of FIPG sealant. (Part No. 08826-00090), (Three Bond 1281) or equivalent to oil pan. See Fig. 14 . Reinstall transmission oil pan. Tighten bolts to specification. Install drain plug and tighten to specification. See TORQUE SPECIFICATIONS . With engine off, add NEW fluid through oil filler tube. 3. Start engine and move gearshift lever through all positions. Place gearshift lever back into Park. Check fluid level. Add fluid to bring level up to COOL mark on dipstick. 4. Recheck fluid level when engine and transmission reaches operating temperature of 158-176F (7080C). Add fluid up to HOT mark on dipstick. See FLUID CAPACITIES .

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Fig. 12: Removing Oil Pan Sealer Using Gasket Cutter Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 13: Removing & Installing Fluid Filter & Gaskets Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

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Fig. 14: Installing Bead Of Sealer To Oil Pan Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
A-44D (Tacoma)

1. Raise and support vehicle. Remove drain plug and drain transmission fluid. Remove the 14 bolts and transmission oil pan and gasket. Carefully remove the oil pan. Inspect for excess debris in bottom of oil pan. Remove oil pipes by prying both ends of pipes down to access fluid filter. See Fig. 15 . 2. Remove bolts, transmission fluid filter and gasket. See Fig. 16 . Thoroughly clean transmission oil pan. Install transmission fluid filter and gasket. Install oil pipes by lightly tapping on the ends using a plastic hammer. Install a NEW oil pan gasket. Install oil pan and tighten bolts to specification. See TORQUE SPECIFICATIONS . Fill transmission through dipstick tube to specified capacity using recommended fluid. See RECOMMENDED FLUIDS . 3. Ensure vehicle is on a level surface. Apply parking brake. Start engine and apply brakes. Bring engine to operating temperature. Move gearshift lever through all gears, ending in Park. Recheck fluid level and add as necessary. DO NOT overfill.

2001-02 AUTOMATIC TRANSMISSIONS Servicing - Toyota

Fig. 15: Removing & Installing Oil Pipes (A-44D) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

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Fig. 16: Removing & Installing Fluid Filter & Gasket (A-44D) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
A-541E (Avalon, Camry, Solara & Sienna)

1. Raise and support the vehicle. Using a hexagon wrench, remove the drain plug and drain fluid. Remove 17 oil pan bolts, and carefully remove the oil pan assembly. Discard the gasket. Remove the 3 bolts and fluid filter. See Fig. 17 . Clean the oil pan. 2. Install the fluid filter. Install and tighten the 3 bolts. See TORQUE SPECIFICATIONS . Install the 3 magnets in indentations of the oil pan. Install oil pan and a NEW gasket. Install and tighten the 17 bolts. See TORQUE SPECIFICATIONS .

2001-02 AUTOMATIC TRANSMISSIONS Servicing - Toyota

Fig. 17: Removing & Installing Fluid Filter Assembly (A-541E) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
U-140 Series & U-240 Series (Camry, Celica, Highlander, Solara & RAV4)

1. Raise and support vehicle. Remove the 18 oil pan bolts and oil pan. Remove the gasket and the 2 magnets from oil pan. Clean oil pan for reassembly. Disconnect the 5 shift solenoid valve connectors. Remove the fluid temperature sensor wiring harness bolt and remove sensor. See Fig. 99 . Remove the fluid filter assembly. See Fig. 100 . Remove the "O" ring from the filter. 2. Coat the NEW fluid filter "O" ring with ATF and install, with the 3 bolts. See Fig. 100 . Coat the NEW "O" ring for the fluid temperature sensor with ATF and install with the lock plate and bolt. Connect the 5 shift solenoid valve connectors. Install the 2 magnets in oil pan and install oil pan with NEW gasket. Apply THREE BOND, or equivalent, on oil pan bolts. Tighten to specification. See TORQUE SPECIFICATIONS .
U-340E & U-341E (Celica & ECHO)

1. Raise and support vehicle. Remove left side engine undercover. Remove drain plug and drain ATF. Remove oil pan and gasket. Remove the 3 bolts and fluid filter. Clean oil pan and magnets.

2001-02 AUTOMATIC TRANSMISSIONS Servicing - Toyota

2. Install the "O" ring on fluid filter. Install the fluid filter with the 3 bolts. Install the 2 magnets in oil pan. Install oil pan and a NEW gasket with the 19 bolts. Install a NEW gasket and drain plug. Install left side engine undercover. Add ATF and check fluid level. See LUBRICATION .
P-111 (Prius)

1. Drive vehicle until engine and transmission reach normal operating temperature. Park vehicle on level surface and apply parking brake. With engine idling and brakes applied, move gearshift lever through all positions ending in "P" position. Turn engine off. 2. Raise and support vehicle. Carefully remove the transaxle drain plug and drain ATF into a suitable container. See Fig. 18 . Remove the 12 oil pan bolts and remove the oil pan and gasket. 3. Remove the magnet from the oil pan and clean all metallic particles from the magnet. See Fig. 19 . Remove the bolt and oil strainer. See Fig. 20 . 4. Clean the oil pan and dry using compressed air. Install the magnet back into oil pan in the original position. Install a NEW gasket and install the oil pan and bolts. Tighten bolts to specification. See TORQUE SPECIFICATIONS . Remove filler plug. See Fig. 9 . Fill transmission to specification with proper fluid. See FLUID CAPACITIES . Apply liquid sealer to threads of filler plug and install. Tighten to specification. See TORQUE SPECIFICATIONS .

Fig. 18: Locating Transaxle Drain Plug (Prius) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

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Fig. 19: Locating Transaxle Oil Pan Magnet (Prius) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

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Fig. 20: Removing & Installing Oil Strainer & Bolt (Prius) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

ON-VEHICLE REPAIRS

2001-02 AUTOMATIC TRANSMISSIONS Servicing - Toyota

Various components may be serviced without transmission removal, depending on application. For servicing of these components, see appropriate component under ADJUSTMENTS and/or REMOVAL & INSTALLATION . For additional information on testing electrical components, see appropriate DIAGNOSIS article.

ADJUSTMENTS
WARNING: Vehicles are equipped with Supplemental Inflatable Restraint (SIR) system. When servicing vehicles, use care to avoid accidental air bag deployment. SIR system-related components are located in various locations throughout interior and exterior of vehicles, depending on application. Do not use electrical test equipment on or near these circuits. If necessary, deactivate SIR system before servicing components. See appropriate AIR BAG DEACTIVATION PROCEDURES article in GENERAL INFORMATION. SHIFT CABLE
Land Cruiser

1. Apply parking brake. Loosen nut on shift lever on side of transmission. See Fig. 21 . Move control shaft lever fully toward rear of vehicle. 2. Move control shaft lever 2 notches to Neutral position. Place gearshift lever to "N" position. While holding control shaft lever slightly toward Reverse position, tighten control rod nut. 3. Start engine. Ensure vehicle moves forward when moving gearshift lever from "N" to "D" position, and rearward when shifting to "R" position.

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Fig. 21: Adjusting Shift Cable (Land Cruiser) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Tacoma & 4Runner With Floor Shift

1. Raise and support vehicle. Apply parking brake. Loosen nut on shift lever on side of transmission. See Fig. 22 . Move control shaft lever fully toward rear of vehicle. 2. Push control rod forward 2 notches to Neutral position. Set gearshift lever to "N" position. Tighten nut for control rod at gearshift. While holding control shaft lever slightly toward "R" position, tighten control rod nut. 3. Start engine. Ensure vehicle moves forward when shifting gearshift lever from "N" to "D" position, and rearward when shifting to "R" position.

Fig. 22: Adjusting Gearshift Cable With Floor Shift Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Tacoma With Column Shift

1. Apply parking brake. Loosen swivel nut on manual shift lever on side of transmission. See Fig. 23 . Move manual shift lever downward to Park position. 2. Move manual shift lever upward 2 notches to Neutral position. Set gearshift lever to "N" position. While holding manual gearshift lever slightly toward "R" position, tighten swivel nut. 3. Start engine. Ensure vehicle moves forward when shifting gearshift from "N" to "D" position, and moves rearward when shifting to "R" position.

2001-02 AUTOMATIC TRANSMISSIONS Servicing - Toyota

Fig. 23: Adjusting Gearshift Cable With Column Shift (Tacoma) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. PARK/NEUTRAL POSITION SWITCH NOTE: Park/Neutral Position switch may also be referred to as PNP switch.

1. Check if engine can be started with gearshift lever only in "N" or "P" positions. If adjustment is needed, loosen PNP switch retaining bolt(s). Position gearshift in Neutral. Align neutral line on PNP switch with groove on shaft. See Fig. 24 or Fig. 25 . 2. Hold PNP switch in this position and tighten retaining bolt to specification. See TORQUE SPECIFICATIONS . Ensure vehicle only starts with gearshift lever in "P" or "N" position.

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Fig. 24: Adjusting Park/Neutral Position Switch (Except Avalon) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

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Fig. 25: Adjusting Park/Neutral Position Switch (Avalon) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. THROTTLE VALVE CABLE
Avalon, Camry, Corolla, RAV4, Sienna, Solara, Tacoma, Tundra & 4Runner

1. Ensure accelerator pedal is in released position and throttle valve is fully closed. No slack should exist in throttle valve cable at throttle body. Measure distance between outer cable and stopper on throttle valve cable. See Fig. 26 . 2. Loosen adjusting nuts on throttle valve cable. Tighten or loosen adjusting nuts until proper distance is obtained. On Avalon, distance should be .031-.059" (.80-1.50 mm). On all other models, distance should be 0-.04" (0-1.0 mm). Tighten adjusting nuts. Recheck distance once adjusting nuts are tightened.

Fig. 26: Measuring Distance Of Throttle Valve Cable Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

REMOVAL & INSTALLATION

WARNING: Vehicles are equipped with Supplemental Inflatable Restraint (SIR) system. When servicing vehicles, use care to avoid accidental air bag deployment. SIR system-related components are located in various locations throughout interior and exterior of vehicles, depending on application. Do not use electrical test equipment on or near these circuits. If necessary, deactivate SIR system before servicing components. See AIR BAG DEACTIVATION PROCEDURES article in

2001-02 AUTOMATIC TRANSMISSIONS Servicing - Toyota

Fig. 50: Disassembled View Of Oil Cooler Components (Sequoia & Tundra) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. PARK/NEUTRAL POSITION SWITCH
Removal & Installation (Corolla)

1. To remove, disconnect control cable from the control shaft lever. Remove the nut, washer and control shaft lever. Using a screwdriver, pry off the locking washer. Remove the nut and the locking washer. See Fig. 51 . Remove the 2 bolts and the PNP switch. 2. Install the PNP switch with 2 bolts. Install the nut stopper and the nut. Stake the nut with the lock

2001-02 AUTOMATIC TRANSMISSIONS Servicing - Toyota

plate. Install the control shaft lever, washer and nut. Connect the control cable to the control shaft lever. Check that the engine starts with the gearshift lever only in the Neutral or Park position, but not in any other position. If not, carry out the adjustment procedure. See PARK/NEUTRAL POSITION SWITCH under ADJUSTMENTS.

Fig. 51: Removing & Installing PNP Switch Assembly (Corolla) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Removal & Installation (2001 Camry & Solara - A140E)

1. Remove engine undercover and control shaft lever nut and control shaft lever. Disconnect the PNP switch connector and pry off the lock plate. See Fig. 52 . Remove the 2 PNP switch retaining bolts. Remove switch. 2. Install PNP switch with the 2 bolts. Tighten to 48 INCH lbs. (5.4 N.m). Install a NEW lock plate and nut. Tighten to 61 INCH lbs. (6.9 N.m). Bend the claws on lock plate to fix the nut. Go to next step. 3. Install the control shaft lever, washer and nut. Tighten to 133 INCH lbs. (15 N.m). Connect PNP switch wiring connector and check for proper operation. Vehicle should only start in the Neutral and Start positions. Go to next step. 4. If the switch does not operate properly, see PARK/NEUTRAL POSITION SWITCH under ADJUSTMENTS.

2001-02 AUTOMATIC TRANSMISSIONS Servicing - Toyota

2. Remove bolts, transmission fluid filter and gasket. Remove the 2 oil pipe bracket bolts. See Fig. 10 . Remove the 4 oil pipes, using a screwdriver to gently pry down. See Fig. 59 . Go to next step. 3. Remove the manual detent spring and manual valve body. See Fig. 60 . Remove the 14 valve body bolts. Disconnect throttle valve cable and the valve body. See Fig. 61 . Remove the 2nd brake apply gasket and governor oil strainer. See Fig. 62 . 4. To install, replace the brake apply gasket. Connect throttle valve cable, being careful not to pinch the solenoid wiring. Install valve body and bolts. See Fig. 63 . Tighten to specification. See TORQUE SPECIFICATIONS . Go to next step. 5. Install the manual valve body and manual valve. Tighten bolts to specification. Install the 4 oil pipes and oil pipe bracket and bolts. Tighten to specification. Install the fluid filter and bolts. Tighten to specification. See TORQUE SPECIFICATIONS . Install magnets in the oil pan, install a NEW oil pan gasket and install and tighten drain plug. Fill with proper fluid to correct level. See LUBRICATION .

Fig. 59: Removing & Installing Oil Pipes (A-131L) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2001-02 AUTOMATIC TRANSMISSIONS Servicing - Toyota

Fig. 60: Removing Manual Detent Spring & Manual Valve Body (A-131L) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2001-02 AUTOMATIC TRANSMISSIONS Servicing - Toyota

Fig. 61: Disconnecting & Connecting Throttle Valve Cable (A-131L) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

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Fig. 62: Removing & Installing 2nd Brake Apply Gasket & Oil Strainer (A-131L) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

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Fig. 63: Installing & Torquing Valve Body Bolts (A-131L) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Removal & Installation (Camry & Solara A-140E)

1. Raise and support the vehicle. Remove engine undercover. Remove drain plug and drain ATF. Remove the oil pan bolts, and carefully remove oil pan assembly. See DRAINING & REFILLING under LUBRICATION. Discard the gasket. Go to next step. 2. Remove the detent spring on manual valve body. See Fig. 64 . Remove the manual valve body. Remove fluid filter assembly. Remove the oil pipe bracket. Disconnect the solenoid connectors. See Fig. 65 . Carefully pry up on the 4 oil pipes using a large screwdriver. See Fig. 66 . Remove the oil pipes. Go to next step. 3. Remove the 12 valve body bolts. Remove the throttle valve cable. See Fig. 61 . Remove the valve body. Remove the 2nd brake apply gasket. Remove shift solenoid valves No. 1 and 2. See Fig. 67 . Remove the 2 "O" rings from both solenoids. 4. For assembly, coat NEW "O" rings with ATF and install on the shift solenoids. Install both shift solenoids into valve body. Tighten to specification. See TORQUE SPECIFICATIONS . While holding the cam down by hand, slip the cable end into the slot, being careful not to pinch any wiring. Go to next step.

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Fig. 69: Installing Oil Feed Pipes (A-140E) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 70: Installing Fluid Filter Bolts (A-140E) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Removal & Installation (Corolla A-245E)

2001-02 AUTOMATIC TRANSMISSIONS Servicing - Toyota

1. Raise and support vehicle. Remove left side engine undercover. Remove drain plug and drain ATF. Remove the 18 bolts. Discard the gasket. Remove the 3 bolts, fluid filter and gasket. See Fig. 71 . Disconnect 3 solenoid connectors. See Fig. 72 . Remove the bolt and manual detent spring. See Fig. 73 . Go to next step. 2. Remove the bolt and wire retainer. See Fig. 74 . Remove the 17 bolts. See Fig. 77 . Disconnect throttle valve cable from the cam. While disconnecting the manual valve connecting rod from the manual valve lever, remove valve body with the manual valve together. See Fig. 76 . 3. To install, while connecting the manual valve connecting rod to the manual valve lever, install valve body with the manual valve together. Connect throttle valve cable to the cam. Install the 17 bolts. Install wire retainer and bolt. Install manual detent spring and bolt. Go to next step. 4. Connect 3 solenoid connectors. Install a NEW gasket to fluid filter. Install fluid filter and gasket with the 3 bolts. See Fig. 11 . Install 2 magnets in oil pan. Install a NEW gasket on the oil pan and install on transaxle. Install the 18 bolts and drain plug. Install left side engine undercover. Fill with proper fluid to correct level. See LUBRICATION .

Fig. 71: Removing & Installing Fluid Filter (A-245E) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2001-02 AUTOMATIC TRANSMISSIONS Servicing - Toyota

Fig. 72: Disconnecting & Connecting Solenoid Connectors (A-245E) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2001-02 AUTOMATIC TRANSMISSIONS Servicing - Toyota

Fig. 73: Removing & Installing Manual Detent Spring (A-245E) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2001-02 AUTOMATIC TRANSMISSIONS Servicing - Toyota

Fig. 74: Removing & Installing Wire Retainer Bolt (A-245E) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

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Fig. 75: Disconnecting & Connecting Throttle Valve Cable At Cam (A-245E) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

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Fig. 76: Removing & Installing Manual Valve With Valve Body (A-245E) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

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Fig. 77: Tightening Valve Body Bolts & Bolt Length (A-245E) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Removal & Installation (Land Cruiser, Sequoia, Tacoma, Tundra & 4Runner A-340E, A-340F & A-343F)

CAUTION: When working with FIPG sealing material, you must observe the following: Using a razor blade and gasket scraper, remove all of FIPG sealing material from the gasket surfaces. Thoroughly clean all components to remove all loose material. Clean both sealing surfaces with a non-residue solvent. Apply FIPG in an approximately 0.04" (1 mm) wide bead along the sealing surface. Parts must be assembled within 10 minutes of application. Otherwise, the FIPG sealing material must be removed and reapplied. 1. Raise and support the vehicle. Remove oil pan. See DRAINING & REFILLING under LUBRICATION. Remove fluid filter. See Fig. 81 or Fig. 82 . Remove oil pipes (if equipped). Disconnect all the shift solenoid connectors. Remove the valve body bolts and lower valve body. On models with 4.7L engines, disconnect throttle valve cable from the cam. See Fig. 80 . Go to next step. 2. Disconnect wiring harness connectors from shift solenoids. Remove shift solenoid valve lock plate bolts and shift solenoid valves. See Fig. 78 . Remove the "O" rings from shift solenoid valves. On models with 3.4L engines, remove the detent spring and manual valve.

2001-02 AUTOMATIC TRANSMISSIONS Servicing - Toyota

3. To install, on models with 3.4L engines, install manual valve and the detent spring and tighten bolts to specification. See TORQUE SPECIFICATIONS . Install NEW "O" rings on the shift solenoid valves. Go to next step. 4. Install the shift solenoid valves and lock plate with the bolts. Tighten to specification. See TORQUE SPECIFICATIONS . Align the groove of the manual valve with pin of lever. Install valve body and bolts. See Fig. 83 -Fig. 87 . Tighten to specification. See TORQUE SPECIFICATIONS . Go to next step. 5. Install shift solenoid wiring harness connectors. On models with 4.7L engines, connect the throttle valve cable from the cam. Install fluid filter. Install oil pipes if equipped. Install oil pan and bolts. Tighten to specification. See TORQUE SPECIFICATIONS . Fill with proper fluid to correct level. See LUBRICATION .

2001-02 AUTOMATIC TRANSMISSIONS Servicing - Toyota

Fig. 113: Staking Throttle Valve Cable (Avalon) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. THROTTLE VALVE CABLE (COROLLA A-131L)
Removal

1. Disconnect throttle valve cable from throttle body. See Fig. 114 . Remove PNP switch. See PARK/NEUTRAL POSITION SWITCH . Remove valve body. See SHIFT SOLENOIDS & VALVE BODY . 2. Remove retaining bolt and plate. Pull out cable from transaxle.
Installation

1. If original cable is used, begin at step C . If throttle valve cable is NEW, perform operations -B first: A. Bend cable so that there is a radius of about 7.87" (200 mm). B. Pull inner cable lightly until resistance is slightly felt, and hold it there. C. Stake the stopper, 0.031-0.059" (.8-1.5 mm) from the end of the outer cable. D. Install a NEW "O" ring to throttle valve cable. E. Pull in throttle valve cable and install retaining bolt. Tighten to specification. See TORQUE SPECIFICATIONS . 2. Install valve body. See SHIFT SOLENOIDS & VALVE BODY . Install PNP switch. See PARK/NEUTRAL POSITION SWITCH . Go to next step. 3. Connect throttle valve cable to throttle body. Install drain plug. Add proper fluid and check fluid level. See LUBRICATION .

2001-02 AUTOMATIC TRANSMISSIONS Servicing - Toyota

Fig. 114: Removing & Installing Throttle Valve Cable (Corolla A-131L) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. THROTTLE VALVE CABLE (2001 CAMRY & SOLARA)
Removal

1. Disconnect the throttle valve cable from throttle linkage. Disconnect the cable from the cable clamps in the engine compartment. 2. Remove PNP switch. See PARK/NEUTRAL POSITION SWITCH . Remove valve body. See SHIFT SOLENOIDS & VALVE BODY . 3. Remove the retaining bolt and plate. Pull out cable from transaxle case.
Installation

1. If original cable is used, begin at step C . If throttle valve cable is NEW, perform operations -B first: A. Bend cable so that there is a radius of about 7.87" (200 mm). B. Pull inner cable lightly until resistance is slightly felt, and hold it there. C. Stake the stopper, 0.031-0.059" (.8-1.5 mm) from the end of the outer cable. D. Install a NEW "O" ring to throttle valve cable. E. Pull in the throttle valve cable and install retaining bolt. Tighten to specification. See TORQUE SPECIFICATIONS . 2. Install valve body. See SHIFT SOLENOIDS & VALVE BODY . Install PNP switch. See PARK/NEUTRAL POSITION SWITCH .

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Fig. 126: Removing & Installing No. 2 VSS (Land Cruiser) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. VEHICLE SPEED SENSOR (GEAR DRIVEN) NOTE: For transaxle application, see GEAR DRIVEN SPEED SENSOR APPLICATION table.

GEAR DRIVEN SPEED SENSOR APPLICATION Application Camry Celica Corolla ECHO RAV4 Solara Tacoma

Trans. Model A-140E, U-241E & A-541E U-240E & U-341E A-131L & A-245E U-340E U-341E A-140E & A-541E A-44D

2001-02 AUTOMATIC TRANSMISSIONS Servicing - Toyota

Camry, Celica, Corolla, ECHO, RAV4 & Solara

Disconnect Vehicle Speed Sensor (VSS) wiring harness connector. Remove the bolt and VSS assembly. Remove the clip and speedometer driven gear from the speed sensor. See Fig. 127 . Remove the "O" ring from VSS. To install, coat a NEW "O" ring with ATF and install it onto VSS. Install speedometer driven gear into VSS and the clip. Install VSS assembly and tighten bolt to specification. See TORQUE SPECIFICATIONS .

Fig. 127: Removing & Installing VSS Assembly (Except Tacoma) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Removal & Installation (Tacoma A44D)

1. Remove the bolt and the vehicle speed sensor assembly. See Fig. 128 . Remove the clip and the driven gear from the vehicle speed sensor. Remove the "O" ring from the vehicle speed sensor. 2. Coat a NEW "O" ring with ATF and install it on vehicle speed sensor. Install the driven gear and the clip on vehicle speed sensor. Install vehicle speed sensor assembly with the bolt. Tighten to specification. See TORQUE SPECIFICATIONS .

2001-02 AUTOMATIC TRANSMISSIONS Servicing - Toyota

Fig. 128: Removing & Installing Vehicle Speed Sensor (Tacoma A-44D) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS (CARS) Application Air Cleaner Bracket (ECHO) Transaxle/Transmission Oil Cooler Pipe Bolt Avalon, Camry, Celica ECHO & Solara Transaxle/Transmission Oil Cooler Pipe Elbow Bolt Avalon, Camry, Celica, ECHO & Solara Transaxle/Transmission Oil Pan Drain Plug Avalon, Camry, Celica, Corolla, ECHO, Solara & Prius Vehicle Speed Sensor Bolt (Celica U-240E) Counter Gear Speed Sensor Bolt (Camry, Celica, & Solara) Cruise Control Actuator Direct Clutch Speed Sensor Bolt (Avalon Camry, ECHO & Solara) Fill Plug (U-140E, U-140F & U-240E) Input Turbine Speed Sensor Bolt (Celica U-240E & Solara U-241E) Manual Detent Spring Bolt (Corolla A-245E) Ft. Lbs. (N.m) 14 (19) 20 (27) 20 (27) 36 (49) 13 (17) INCH Lbs. (N.m) 100 (11.3) 115 (13) 100 (11.3) 65 (7.4) 100 (11.3) 89 (10)

2001-02 AUTOMATIC TRANSMISSIONS Servicing - Toyota

Manual Valve Body Bolt Avalon Corolla Solara (U-541E) Manual Valve Detent Spring Bolt Avalon Corolla Solara (U-541E) Oil Pipe Bracket Bolt Avalon Camry, Celica, Corolla, ECHO, Solara Park/Neutral Position Switch Retaining Bolt Avalon, Camry, Celica, ECHO & Solara Corolla Park/Neutral Position Switch Retaining Nut Corolla Avalon, Camry, Celica, Corolla, ECHO & Solara Shift Solenoid Valve Bolt Avalon (SL, No. 1 & No. 2) Camry Bolt "A" 0.47" (12 mm) (1) Bolt "B" 1.77" (45 mm) (1) Celica Bolt "A" 0.47" (12 mm) (1) Bolt "B" 1.77" (45 mm) (1) ECHO Bolt "A" 0.55" (14 mm) Bolt "B" 2.17 (55 mm) Solara A-140E (No. 1 & No. 2) A-541E U-241E Bolt "A" 0.47" (12 mm) Bolt "B" 1.77 (45 mm) Shift Solenoid Valve Wiring Bolt Throttle Cable Bolt (At Transaxle/Transmission) Avalon Camry & Solara A-140E A-541E Corolla Transaxle/Transmission Fluid Filter Bolt Avalon

97 (11) 89 (10) 97 (11) 97 (11) 89 (10) 97 (11) 58 (6.6) 89 (10) 48 (5.4) 115 (13) 35 (3.9) 61 (6.9) 58 (6.6) 58 (6.6) 96 (10.8) 58 (6.6) 96 (10.8) 58 (6.6) 97 (11) 48 (5.4) 58 (6.6) 58 (6.6) 96 (10.8) 48 (5.4) 48 (5.4) 89 (10) 48 (5.4) 89 (10)

2001-02 AUTOMATIC TRANSMISSIONS Servicing - Toyota

A-541E Bolt "A" 0.866" (22 mm) (2) Bolt "B" 2.087" (53 mm) (2) Camry A-140E A-541E Bolt "A" 0.866" (22 mm) (2) Bolt "B" 2.087" (53 mm) (2) U-241E Celica ECHO Solara A-140E A-541E Bolt "A" 0.866" (22 mm) (2) Bolt "B" 2.087" (53 mm) (2) U-241E Corolla Transaxle/Transmission Oil Pan Bolt Avalon Camry A-140E A-541E U-241E Celica Corolla A-131L A-245E ECHO Solara (A-140E) Solara (A-541E) & (U-241E) Valve Body-To-Case Bolt Avalon Camry Solara A-140E A-541E U-241E Celica (U-240E & U-341E) Corolla A-131L A-245E ECHO 89 (10) 97 (11) 97 (11) 89 (10) 97 (11) 96 (10.8) 97 (11) 97 (11) 89 (10) 89 (10) 97 (11) 96 (10.8) 89 (10) 69 (7.8) 43 (4.9) 67 (7.6) 69 (7.8) 69 (7.8) 43 (4.9) 47 (5.3) 69 (7.8) 43 (4.9) 69 (7.8) 97 (11) 96 (10.8) 89 (10) 97 (11) 96 (10.8) 97 (11) 89 (10) 57 (6.4) 97 (11)

2001-02 AUTOMATIC TRANSMISSIONS Shift Interlock Systems - Lexus & Toyota

DESCRIPTION & OPERATION

WARNING: Vehicle is equipped with Supplemental Inflatable Restraint (SIR) system. When servicing vehicle, use care to avoid accidental air bag deployment. SIR system-related components are located in various locations throughout interior and exterior of vehicle, depending on application. Do not use electrical test equipment on or near these circuits. If necessary, deactivate SIR system before servicing components. See AIR BAG DEACTIVATION PROCEDURES article in GENERAL INFORMATION. NOTE: Diagnosis and repair information is not available for Toyota Prius. Only wiring diagrams are provided. See WIRING DIAGRAMS .

INTRODUCTION Transaxle/transmission is equipped with an electronically controlled shift interlock and key interlock system. See COMPONENT LOCATIONS . Shift interlock system prevents gearshift lever from being moved from Park unless brake pedal is depressed. In case of a malfunction, gearshift lever can be released by depressing shift interlock override button, located near gearshift lever under small plastic cover (if equipped). Key interlock system prevents ignition key from being moved from ACC to LOCK position on ignition switch unless gearshift lever is in Park position. System consists of brakelight switch (also referred to as stop lamp switch), key interlock solenoid, shift interlock control Electronic Control Unit (ECU), shift interlock solenoid and shift interlock release button. All models may not be equipped with all components. NOTE: Sequoia, Sienna and Tundra models are equipped with cable operated shift interlock system. See SHIFT INTERLOCK SYSTEM OPERATION CHECK (CABLE OPERATED) and ADJUSTMENTS .

SHIFT INTERLOCK SYSTEM With ignition on and brake pedal depressed, an input signal is sent from brakelight switch to ECU. With gearshift lever in Park, an input signal from shift control switch is input to ECU, indicating gearshift lever is in Park. ECU then operates shift interlock solenoid, allowing gearshift lever movement from Park.

COMPONENT LOCATIONS

2001-02 AUTOMATIC TRANSMISSIONS Shift Interlock Systems - Lexus & Toyota

Fig. 10: Shift Interlock & Key Interlock Component Locations (Toyota Corolla) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2001-02 AUTOMATIC TRANSMISSIONS Shift Interlock Systems - Lexus & Toyota

Fig. 13: Shift Interlock & Key Interlock Component Locations (Toyota Tacoma) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 14: Shift Interlock & Key Interlock Component Locations (Toyota 4Runner) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

TROUBLE SHOOTING
PRELIMINARY INSPECTION Diagnosis of shift interlock system should begin with a general visual inspection of related components, i.e., shift linkage, electrical connections, components, etc. Inspect for aftermarket devices which could affect the operation of the shift interlock control system. Inspect easily accessible or visible system components for obvious damage or conditions which could cause the symptom. Intermittent faulty electrical connections or wiring may be the cause of intermittent conditions. Check for loose, bent or corroded terminals and terminal tension. Check for cut, bare or pinched wiring. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving or performing other operations while observing scan tool, DVOM or other testing

2001-02 AUTOMATIC TRANSMISSIONS Shift Interlock Systems - Lexus & Toyota

equipment. See WIRING DIAGRAMS . KEY INTERLOCK SYSTEM OPERATION CHECK Turn ignition on. Depress the brake pedal and move the gearshift lever to any other position than Park. Ensure that the ignition key cannot be turned to Lock. Move the gearshift lever to Park, turn ignition key to Lock position and ensure the ignition key can be removed. SHIFT INTERLOCK RELEASE BUTTON OPERATION CHECK Using a small screwdriver, remove the shift interlock release cover. When moving the gearshift lever with the shift interlock button pressed, ensure the gearshift lever can be moved to any other position, other than Park. SHIFT INTERLOCK SYSTEM OPERATION CHECK (CABLE OPERATED)
Toyota (Sequoia, Sienna & Tundra)

Ensure shift interlock cable does not interfere with wiring harness. Ensure ignition switch turns to LOCK position when gearshift lever is in "P" position. Ensure brake pedal returns fully. Ensure shift interlock is released when brake pedal is depressed with ignition switch in ACC, ON or START position. If system does not operate as specified, see SHIFT INTERLOCK CABLE under ADJUSTMENTS.

COMPONENT TESTS
KEY INTERLOCK SOLENOID NOTE: For circuit reference, see CONNECTOR IDENTIFICATION and/or WIRING DIAGRAMS . Not all vehicles are equipped with a key interlock solenoid.

NOTE:

Lexus GS300 & GS430

1. Disconnect the solenoid connector. Using an ohmmeter, measure the resistance between terminals. See Fig. 15 . Resistance should be 12-17 ohms. If resistance value is not as specified, replace the solenoid. See KEY INTERLOCK SOLENOID under REMOVAL & INSTALLATION. 2. Momentarily supply battery positive voltage and ground at terminals. See Fig. 16 . Ensure an operating noise can be heard from the solenoid. If the solenoid does not operated, replace the solenoid. See KEY INTERLOCK SOLENOID under REMOVAL & INSTALLATION.

2001-02 AUTOMATIC TRANSMISSIONS Shift Interlock Systems - Lexus & Toyota

Fig. 20: Measuring Resistance At Key Interlock Solenoid (Lexus & Toyota - Floor Shift) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2001-02 AUTOMATIC TRANSMISSIONS Shift Interlock Systems - Lexus & Toyota

Fig. 21: Testing Operation Of Key Interlock Solenoid (Lexus & Toyota - Floor Shift) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Lexus SC430

Disconnect solenoid connector. Momentarily supply battery voltage to terminal KLS+ and ground terminal KLS-. See Fig. 118 . Ensure an operating sound is heard. If the solenoid does not operate, replace the solenoid. See KEY INTERLOCK SOLENOID under REMOVAL & INSTALLATION.
Toyota Avalon (Column Shift)

1. Disconnect the solenoid connector. Using an ohmmeter, measure the resistance between terminals. See Fig. 22 . Resistance should be 12.5-16.5 ohms. If resistance value is not as specified, replace the solenoid. See KEY INTERLOCK SOLENOID under REMOVAL & INSTALLATION. 2. Momentarily supply battery positive voltage and ground at terminals. See Fig. 23 . Ensure an operating noise can be heard from the solenoid. If the solenoid does not operate, replace the solenoid. See KEY INTERLOCK SOLENOID under REMOVAL & INSTALLATION.

2001-02 AUTOMATIC TRANSMISSIONS Shift Interlock Systems - Lexus & Toyota

Fig. 22: Measuring Resistance At Key Interlock Solenoid (Toyota Avalon - Column Shift) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 23: Testing Operation Of Key Interlock Solenoid (Toyota Avalon - Column Shift) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2001-02 AUTOMATIC TRANSMISSIONS Shift Interlock Systems - Lexus & Toyota

Toyota Avalon (Floor Shift) & Camry Solara

1. Disconnect the solenoid connector. Using an ohmmeter, measure resistance between terminals. See Fig. 20 . Resistance should be 13-16 ohms. If resistance value is not as specified, replace the solenoid. See KEY INTERLOCK SOLENOID under REMOVAL & INSTALLATION. 2. Apply battery positive voltage and ground to terminals. See Fig. 21 . Ensure an operating noise can be heard from the solenoid. If the solenoid does not operated, replace the solenoid. See KEY INTERLOCK SOLENOID under REMOVAL & INSTALLATION.
Toyota Corolla

1. Disconnect the solenoid connector. Using an ohmmeter, measure resistance between terminals. See Fig. 24 . Resistance should be 12.5-16.5 ohms. If resistance value is not as specified, replace the solenoid. See KEY INTERLOCK SOLENOID under REMOVAL & INSTALLATION. 2. Momentarily supply battery positive voltage and ground at terminals. See Fig. 25 . Ensure that an operating noise can be heard from the solenoid. If the solenoid does not operate, replace the solenoid. See KEY INTERLOCK SOLENOID under REMOVAL & INSTALLATION.

Fig. 24: Measuring Resistance At Key Interlock Solenoid (Toyota Corolla) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2001-02 AUTOMATIC TRANSMISSIONS Shift Interlock Systems - Lexus & Toyota

Fig. 25: Testing Operation Of Key Interlock Solenoid (Toyota Corolla) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Toyota Highlander

Momentarily supply battery positive voltage and ground at terminals No. 3 and 4. See Fig. 118 . Ensure that an operating noise can be heard from the solenoid. If the solenoid does not operate, replace the solenoid. See KEY INTERLOCK SOLENOID under REMOVAL & INSTALLATION.
Toyota RAV4

1. Disconnect the solenoid connector. Using an ohmmeter, measure resistance between terminals. See Fig. 26 . Resistance should be 12.5-16.5 ohms. If resistance value is not as specified, replace the solenoid. See KEY INTERLOCK SOLENOID under REMOVAL & INSTALLATION. 2. Disconnect solenoid connector. Momentarily supply battery voltage to terminal KLS+ and ground terminal KLS-. See Fig. 27 . Ensure an operating sound is heard. If the solenoid does not operate, replace the solenoid. See KEY INTERLOCK SOLENOID under REMOVAL & INSTALLATION.

2001-02 AUTOMATIC TRANSMISSIONS Shift Interlock Systems - Lexus & Toyota

SHIFT INTERLOCK CONTROL SWITCH NOTE: For circuit reference, see CONNECTOR IDENTIFICATION and/or WIRING DIAGRAMS . On models not listed, shift interlock control switch is incorporated in shift interlock ECU. No voltage tests for shift interlock control switch circuits are available.

NOTE:

Lexus & Toyota

Disconnect the shift interlock switch. See COMPONENT LOCATIONS . Using a DVOM, check for continuity between specified terminals. See Fig. 32 -Fig. 38 . If continuity is not as specified, replace the switch.

Fig. 32: Checking For Continuity At Shift Interlock Switch (Lexus IS300) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2001-02 AUTOMATIC TRANSMISSIONS Shift Interlock Systems - Lexus & Toyota

Fig. 77: Exploded View Of Trim Panels (Toyota) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2001-02 AUTOMATIC TRANSMISSIONS Shift Interlock Systems - Lexus & Toyota

Fig. 82: Routing Location Of Shift Interlock Cable (Toyota) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2001-02 AUTOMATIC TRANSMISSIONS Shift Interlock Systems - Lexus & Toyota

Fig. 83: Locating Locking Pin (Toyota) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2001-02 AUTOMATIC TRANSMISSIONS Shift Interlock Systems - Lexus & Toyota

Fig. 84: Installing Shift Interlock Cable To Sliding Block (Toyota) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. SHIFT INTERLOCK ELECTRONIC CONTROL UNIT
Removal & Installation (Lexus ES300)

Manufacturer does not provide removal and installation procedures for this model. For an exploded view of related components, see Fig. 60 .
Removal & Installation (Lexus GS300 & GS430)

Manufacturer does not provide shift interlock electronic control unit removal and installation procedure. See Fig. 1 and Fig. 85 .

2001-02 AUTOMATIC TRANSMISSIONS Shift Interlock Systems - Lexus & Toyota

Fig. 101: Exploded View Of Floor Shift Assembly (Toyota Celica) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Removal & Installation (Toyota Corolla)

1. Remove the left front door scuff plate, left side cowl side trim, right front door scuff plate and the right side cowl side trim. Remove the lower finish panel, left side lower insert, and the left and right side lower trim panels. See Fig. 102 . 2. Remove the front ash tray box, center lower cluster finish panel, stereo opening cover and gearshift

2001-02 AUTOMATIC TRANSMISSIONS Shift Interlock Systems - Lexus & Toyota

3. 4.

5. 6.

bezel. Remove the rear console box, lower center finish panel. See Fig. 102 . Disconnect shift control cable and remove the 4 bolts. See Fig. 103 . Disconnect the 2 connectors and remove the shift lever assembly. Remove the 2 screws and the shift interlock ECU. To assemble, install shift interlock ECU with the 2 screws. Install the floor shift assembly with 4 screws, the 2 connectors and connect the shift cable. See Fig. 103 . Install the center lower finish panel, rear console box, gearshift bezel and the stereo opening cover. See Fig. 102 . Install the center lower cluster finish panel, front ash tray, right side lower panel and the lower panel. Install the left side lower insert and lower finish panel. See Fig. 102 . Install the left and right side cowl trim, right side scuff plate and the left side scuff plate. See Fig. 102 .

Fig. 102: Exploded View Of Floor Console & Related Components (Toyota Corolla) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2001-02 AUTOMATIC TRANSMISSIONS Shift Interlock Systems - Lexus & Toyota

Fig. 103: Exploded View Of Floor Shift Assembly & Related Components (Toyota Corolla) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Removal & Installation (Toyota ECHO)

Remove floor shift assembly. See SHIFT INTERLOCK CABLE . Disassemble floor shift assembly See Fig. 104 . Remove the shift interlock ECU assembly and remove the shift interlock solenoid. To assemble, install the shift interlock solenoid to the shift interlock ECU assembly. Attach the shift interlock ECU assembly to the floor shift assembly, see Fig. 104 . Install the floor shift assembly. See SHIFT INTERLOCK CABLE .

2001-02 AUTOMATIC TRANSMISSIONS Shift Interlock Systems - Lexus & Toyota

Fig. 135: Measuring Voltage At Shift Interlock ECU (Toyota Celica & RAV4) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 136: Measuring Voltage At Shift Interlock ECU (Toyota Corolla) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 137: Measuring Voltage At Shift Interlock ECU (Toyota ECHO)

SHIFT INTERLOCK SYSTEMS Fig. 152: Shift Interlock System Wiring Diagram (2001 - Toyota Corolla)

2002 CLUTCHES Corolla

2002 CLUTCHES Corolla

APPLICATION
TRANSAXLE APPLICATION Application Corolla (1.8L) Transaxle Model C59 5-Speed

DESCRIPTION & OPERATION

The single, dry-type disc clutch uses a hydraulically operated master cylinder with a clutch release cylinder mounted on clutch housing. Clutch release cylinder is non-adjustable.

ADJUSTMENTS
CLUTCH PEDAL HEIGHT 1. Measure clutch pedal height from highest point of clutch pedal pad to floor panel. See Fig. 1 . Pedal height should be 5.45-5.84" (138.4-148.3 mm). 2. If clutch pedal height adjustment is required, loosen lock nut and rotate bolt at clutch pedal height adjustment point until correct clutch pedal height is obtained. See Fig. 1 . Check clutch pedal free play and push rod play. See CLUTCH PEDAL FREE PLAY & PUSH ROD PLAY .

2002 CLUTCHES Corolla

Fig. 1: Checking Clutch Pedal Height, Push Rod Play & Identifying Adjustment Points Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. CLUTCH PEDAL FREE PLAY & PUSH ROD PLAY 1. Remove lower finish panel using the following steps: A. Remove 2 bolts holding lower finish panel and remove panel. See Fig. 2 B. Disconnect the hood lock control cable. 2. Remove 2 bolts holding lower insert and remove insert. 3. Remove No. 2 heater to register duct. 4. Check clutch pedal free play. Push clutch pedal downward until beginning of clutch resistance is felt. See Fig. 3 . Note distance of clutch pedal movement. Clutch pedal free play should be .039.197" (1.00-5.00 mm). 5. Check push rod play. Slightly push clutch pedal downward until slight resistance is felt (point where push rod just starts to operate clutch master cylinder). Push rod play should be .197-.590" (5.00-15.00

2002 CLUTCHES Corolla

6.

7. 8. 9. 10.

mm) from top of clutch pedal. If push rod play adjustment is required, loosen lock nut on push rod at master cylinder. Rotate push rod to obtain correct push rod play. Tighten lock nut. Recheck clutch pedal free play and clutch pedal height. See Fig. 1 . After adjusting pedal free play, check pedal height. See CLUTCH PEDAL HEIGHT . Install No. 2 heater to register duct. Install lower panel insert with 2 bolts. Install hood lock control cable. Install lower finish panel and bolts.

Fig. 2: Removing/Installing Lower Finish Panel Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 CLUTCHES Corolla

Fig. 3: Measuring Clutch Pedal Free Play Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. CLUTCH PEDAL RELEASE POINT 1. Block wheel and set parking brake. 2. Start engine and allow it to idle. 3. Without depressing clutch pedal, slowly move shift lever into reverse shift slot until gears begin to mesh (gear contact is heard). 4. Gradually depress clutch pedal and measure stroke distance from point gear noise stops to full stroke end position. Distance should be .98" (25.0 mm) or more. See Fig. 4 . 5. If distance is not as specified, check pedal height, push rod play and pedal free play. See CLUTCH PEDAL HEIGHT and CLUTCH PEDAL FREE PLAY & PUSH ROD PLAY . If clutch pedal adjustments are as specified, bleed clutch system. If after bleeding system, distance is still not as specified, inspect clutch cover and disc for excessive wear.

2002 CLUTCHES Corolla

Fig. 4: Measuring Clutch Pedal Release Point Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

TROUBLE SHOOTING
For clutch system symptom diagnosis, see CLUTCH TROUBLE SHOOTING article in GENERAL INFORMATION.

REMOVAL & INSTALLATION

WARNING: Vehicle is equipped with Supplemental Inflatable Restraint (SIR) system. When servicing vehicle, use care to avoid accidental air bag deployment. SIR system-related components are located in various locations throughout interior and exterior of vehicle, depending on application. Do not use electrical test equipment on or near these circuits. If necessary, deactivate SIR system before servicing components. See appropriate AIR BAG DEACTIVATION PROCEDURES article in GENERAL INFORMATION. CAUTION: When battery is disconnected, vehicle computer and memory systems may lose memory data. Driveability problems may exist until computer systems have completed a relearn cycle. See COMPUTER RELEARN PROCEDURES article in GENERAL INFORMATION before disconnecting battery.

2002 CLUTCHES Corolla

CLUTCH ASSEMBLY NOTE:

Removal

To assist with transaxle removal, see Fig. 5 .

1. Disconnect negative battery cable and wait at least 90 seconds. 2. Remove battery and air cleaner case assembly with air intake hose. See Fig. 5 . 3. Remove clutch release cylinder and hydraulic line using the following steps: A. Remove 4 set bolts of the clutch line bracket. See Fig. 6 B. Remove 2 bolts and disconnect the clutch release cylinder and line. 4. Disconnect back-up light switch and vehicle speed sensor connectors. 5. Remove set bolt of ground cable to disconnect the cable from the transaxle. See Fig. 7 . 6. Disconnect transaxle control cable using the following steps: A. Remove the 2 clips and washers. See Fig. 5 . B. Remove the 2 clips from the cables. C. Disconnect the 2 control cables from the transaxle. 7. Remove starter set bolt from transaxle. See Fig. 8 . 8. Remove 2 upper transaxle mounting bolts. 9. Install engine support fixture. See Fig. 9 . 10. Remove 2 left engine mount bolts and left engine mounting stay. See Fig. 10 . 11. Remove 3 left engine mounting bolts and nut. See Fig. 10 . 12. Lower the transaxle side of the engine and remove left mounting bracket bolt and the bracket. See Fig. 11 . 13. Raise and support vehicle. 14. Remove front wheels. 15. Remove right and left engine under covers. 16. Drain transaxle fluid. 17. Remove axle shafts from transaxle. See appropriate AXLE SHAFTS article in DRIVELINE/AXLES. 18. Remove bolts, nut and heat insulator. See Fig. 12 . 19. Remove 2 nuts and brace. See Fig. 5 . 20. Remove front sub-frame and lower suspension arm using the following steps: A. Support the suspension crossmember with a jack. B. Remove 2 set bolts of the stabilizer bar bracket. See Fig. 13 . C. Remove the 14 bolts and nuts. See Fig. 14 . D. Remove the front sub-frame and lower suspension arm. 21. Remove starter using the following steps: A. Disconnect the starter connector. B. Remove the nut and disconnect the starter wire. C. Remove the set bolt of the starter from the lower side. See Fig. 15 . D. Remove the starter.

2002 CLUTCHES Corolla

Using transmission jack for support, slightly raise transaxle. Remove 4 lower side transaxle mounting bolts. See Fig. 16 . Slightly lower left side of engine and remove transaxle. Remove clutch cover and disc using the following steps: A. Place matchmarks on the clutch cover and flywheel for reassembly reference. See Fig. 17 . B. Alternately loosen clutch cover bolts until spring tension is released. C. Remove set bolts and remove clutch cover with clutch disc taking care to not drop the clutch disc. 26. Remove clutch release bearing and fork as an assembly from transaxle. See Fig. 18 . 27. Disassemble clutch release fork and clutch release bearing.

22. 23. 24. 25.

Fig. 5: Exploded View Of Manual Transaxle Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 CLUTCHES Corolla

Fig. 6: Identifying Clutch Release Cylinder & Hydraulic Line Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 CLUTCHES Corolla

Fig. 7: Locating Ground Cable Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 CLUTCHES Corolla

Fig. 8: Locating Starter Set Bolt Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 CLUTCHES Corolla

Fig. 9: Installing Engine Support Fixture Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 CLUTCHES Corolla

Fig. 10: Removing/Installing Left Engine Mounting Stay Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 CLUTCHES Corolla

Fig. 11: Removing/Installing Left Engine Mounting Bracket Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 CLUTCHES Corolla

Fig. 12: Locating Heat Insulator Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 CLUTCHES Corolla

Fig. 13: Removing/Installing Stabilizer Bar Bracket Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 14: Removing/Installing Front Sub-Frame & Lower Suspension Arm

2002 CLUTCHES Corolla

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 15: Removing/Installing Starter Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 CLUTCHES Corolla

Fig. 16: Removing/Installing Lower Side Transaxle Mounting Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 CLUTCHES Corolla

Fig. 17: Removing/Installing Clutch Disc Cover Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 18: Exploded View Of Clutch Assembly

2002 CLUTCHES Corolla

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Inspection

1. Using calipers, check wear on facings of clutch disc by measuring depth of each rivet head. Minimum depth at any rivet is .012" (.30 mm). 2. Using a dial indicator, check clutch disc runout. Replace clutch disc if clutch disc runout is greater than .031" (.79 mm). 3. Using a dial indicator, check flywheel runout. Replace flywheel if runout is greater than .004" (.10 mm). See Fig. 19 . 4. Measure depth and wear on diaphragm spring on clutch cover. Maximum depth is .020" (.51 mm) and maximum width is .236" (6.00 mm). Replace clutch cover if necessary. See Fig. 20 . 5. Ensure clutch release bearing rotates smoothly while applying force in axial direction. Replace clutch release bearing if necessary. 6. After clutch cover installation, using a dial indicator, check diaphragm spring tip alignment. If diaphragm spring tip alignment is greater than .020" (.50 mm), adjust clutch cover spring tips using Tip Adjustment Tool (09333-00013). See Fig. 21 .

Fig. 19: Inspecting Flywheel Runout Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 CLUTCHES Corolla

Fig. 20: Checking Diaphragm Spring Depth & Width Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 CLUTCHES Corolla

Fig. 21: Inspecting & Adjusting Clutch Cover Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Installation

NOTE:

To assist with transaxle installation, see Fig. 5 .

1. When installing flywheel (if removed), flywheel bolt threads are pre-coated from manufacturer. If bolt threads are not pre-coated, apply thread sealant to threads before installing. Install and alternately tighten flywheel bolts in a crisscross pattern to specification. See Fig. 22 . See TORQUE SPECIFICATIONS . 2. Install clutch disc and clutch cover on flywheel using the following steps: A. Insert Clutch Alignment Tool (09301-00210) in clutch disc and insert them on flywheel taking care not to insert the disc in the wrong direction. See Fig. 23 . B. Align the matchmarks on clutch cover and flywheel. C. Install and tighten clutch cover bolts in sequence to specification. See Fig. 17 . See TORQUE SPECIFICATIONS . 3. Using dial indicator with roller attachment, check the diaphragm spring tip alignment. If alignment is greater than maximum non-alignment of .020" (.50 mm), then adjust spring tip alignment with Clutch Diaphragm Spring Aligner (09333-00013). See Fig. 21 . 4. Apply appropriate grease to clutch release fork and release bearing contact point, release fork and

2002 CLUTCHES Corolla

5. 6. 7. 8.

9. 10. 11. 12. 13. 14. 15. 16.

17.

18. 19. 20. 21. 22. 23. 24.

25. 26. 27.

push rod contact point and release fork and pivot point. See Fig. 24 . Apply appropriate grease to clutch input shaft spline. See Fig. 24 . Install clutch release fork and clutch release bearing on transaxle (if removed). Raise and support vehicle. Install transaxle to engine using the following steps: A. Lift up transaxle using a transmission jack. B. Align input shaft with the clutch disc and install transaxle to engine. C. Temporarily tighten 4 lower side transaxle mounting bolts. See Fig. 16 . Lower vehicle. Install left engine mounting bracket with bolt. Tighten to specification. See TORQUE SPECIFICATIONS . See Fig. 11 . Install 3 left engine mounting bracket set bolts and nut. See Fig. 10 . Install left engine mounting stay. See Fig. 10 . Remove engine support fixture. Raise and support vehicle. Tighten 4 lower side transaxle mounting bolts. Remove transmission jack. See Fig. 16 . Tighten to specification. See TORQUE SPECIFICATIONS . Install starter using the following steps: A. Install the starter. See Fig. 15 . B. Temporarily tighten the set bolt of the starter from the lower side. C. Connect the starter connector. D. Install the starter wire with the nut. Install the front sub-frame and lower suspension arm using the following steps: A. Install the front sub-frame and lower suspension arm. B. Install 2 new bolts (A), 12 other bolts (B, C, D and E), and 3 nuts (F). See Fig. 14 . Tighten to specification. See TORQUE SPECIFICATIONS . C. Install 2 set bolts of the stabilizer bar bracket. See Fig. 13 . Install brace with 2 nuts. See Fig. 5 . Install heat insulator with 2 bolts and nut. See Fig. 12 . Install axle shafts from transaxle. See appropriate AXLE SHAFTS article in DRIVELINE/AXLES. Lower vehicle. Install 2 upper side transaxle mounting bolts. See Fig. 8 . Install starter set bolt. See Fig. 8 . Tighten to specification. See TORQUE SPECIFICATIONS . Connect control cable using the following steps: A. Connect the 2 control cables to the transaxle. See Fig. 5 . B. Install 2 clips to the washers. C. Install 2 clips and washers. Install set bolt of the ground cable to transaxle to install ground cable. See Fig. 7 . Connect back-up light switch and vehicle speed sensor connectors. Connect clutch release cylinder and line using the following steps: A. Install the clutch release cylinder with 2 bolts. See Fig. 6 .

2002 CLUTCHES Corolla

28. 29. 30. 31. 32. 33. 34.

B. Install the 4 set bolts of the clutch line bracket. Tighten to specification. See TORQUE SPECIFICATIONS . Install battery and air cleaner case assembly with air hose. See Fig. 5 . Raise and support vehicle. Tighten set bolt of the starter from the lower side. See Fig. 15 . Fill transaxle with oil. See appropriate SERVICING article. Tighten filler plug to specification. See TORQUE SPECIFICATIONS . Install right and left engine under covers. Install and align front wheels. See appropriate WHEEL ALIGNMENT article in SUSPENSION. Road test vehicle. Check for abnormal noises and smooth shifting.

Fig. 22: Installing Flywheel Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 CLUTCHES Corolla

Fig. 23: Installing Clutch Disc On Flywheel Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 CLUTCHES Corolla

Fig. 24: Lubricating Clutch Release Fork Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. CLUTCH MASTER CYLINDER
Removal

NOTE:

To assist with clutch master cylinder removal, see Fig. 25 .

1. Remove brake booster. See appropriate DISC & DRUM article in BRAKES. 2. Using syringe, remove brake fluid from clutch master cylinder. 3. Disconnect hydraulic line with 10 mm Union Nut Wrench (09023-00100) at clutch master cylinder. Use a container to catch the fluid. 4. Remove lower finish panel and panel insert. See CLUTCH PEDAL FREE PLAY & PUSH ROD PLAY under ADJUSTMENTS. 5. Remove No. 2 heater to register duct. 6. Remove clip and clevis pin from push rod assembly at clutch pedal. 7. Remove 2 mounting nuts and remove master cylinder. 8. Remove gasket from master cylinder.

2002 CLUTCHES Corolla

Fig. 25: Exploded View Of Master Cylinder Components Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Installation

NOTE:

To assist with clutch master cylinder installation, see Fig. 25 .

1. Install new gasket to master cylinder. 2. Install master cylinder and 2 mounting nuts. Tighten to specification. See TORQUE SPECIFICATIONS . 3. Install pin and clip. 4. Install No. 2 heater to register duct. 5. Install panel insert and lower finish panel. See CLUTCH PEDAL FREE PLAY & PUSH ROD PLAY under ADJUSTMENTS. 6. Connect hydraulic line to clutch master cylinder. Tighten to specification using torque wrench with a fulcrum length of 11.8" (300 mm). See TORQUE SPECIFICATIONS . 7. Fill clutch reservoir with brake fluid and bleed clutch system. 8. Install brake booster. See appropriate DISC & DRUM article in BRAKES. 9. Adjust clutch pedal height, clutch free play and push rod play. See CLUTCH PEDAL HEIGHT and CLUTCH PEDAL FREE PLAY & PUSH ROD PLAY under ADJUSTMENTS. 10. Check for leaks. CLUTCH RELEASE CYLINDER
Removal

Disconnect hydraulic line at clutch release cylinder using 10 mm union nut wrench. Use a container to catch the fluid. Remove 2 bolts and pull out release cylinder.
Installation

2002 CLUTCHES Corolla

1. Install release cylinder and 2 bolts. See Fig. 6 . 2. Connect hydraulic line at clutch release cylinder. Tighten to specification using torque wrench with fulcrum length of 11.8" (300 mm). See TORQUE SPECIFICATIONS . 3. Fill clutch reservoir with brake fluid and bleed clutch system. 4. Check for leaks.

OVERHAUL
CLUTCH MASTER CYLINDER
Disassembly

NOTE:

To assist with clutch master cylinder disassembly, see Fig. 25 .

1. Remove clutch master cylinder. See CLUTCH MASTER CYLINDER under REMOVAL & INSTALLATION. 2. Loosen lock nut to remove the clevis and remove the lock nut. Remove the boot. 3. Using a pin punch and hammer, tap out the slotted spring pin. Remove reservoir tank and grommet. See Fig. 26 . 4. Using snap pliers, remove snap ring while pushing push rod. Remove push rod and washer. See Fig. 27 . 5. Remove piston.

2002 CLUTCHES Corolla

Fig. 26: Removing/Installing Spring Pin Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 CLUTCHES Corolla

Fig. 27: Removing/Installing Piston Snap Ring Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Reassembly

NOTE:

To assist with clutch master cylinder reassembly, see Fig. 25 .

1. Coat parts with appropriate rubber lubricant. See Fig. 28 . 2. Insert piston into cylinder. 3. Install push rod assembly with new gasket and new washer using the following steps: A. Install the washer to the push rod. B. Using snap ring pliers, install snap ring while pushing the push rod. See Fig. 27 . C. Install boot. 4. Install reservoir tank and new grommet. Using pin punch and hammer, drive slotted spring pin in to reservoir tank until a protrusion of .059-.138" (1.5-3.5 mm) exists. See Fig. 29 .

2002 CLUTCHES Corolla

Fig. 28: Identifying Clutch Master Cylinder Lubrication Points Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 CLUTCHES Corolla

Fig. 29: Installing Slotted Spring Pin Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. CLUTCH RELEASE CYLINDER
Disassembly

NOTE:

To assist with clutch release cylinder disassembly, see Fig. 30 .

1. Remove clutch release cylinder. See CLUTCH RELEASE CYLINDER under REMOVAL & INSTALLATION. 2. Remove bleeder screw. 3. Remove boot with push rod. 4. Remove piston and spring by applying compressed air to bleeder screw and placing shop towel at the end of the release cylinder to catch the piston.
Reassembly

2002 CLUTCHES Corolla

NOTE: 1. 2. 3. 4. 5.

To assist with clutch release cylinder reassembly, see Fig. 30 .

Coat parts with appropriate rubber lubricant. See Fig. 31 . Install piston with spring into cylinder. Install boot with push rod to cylinder. Install 2 union gaskets and union bolt. Tighten to specification. See TORQUE SPECIFICATIONS . Install bleeder plug.

Fig. 30: Exploded View Of Clutch Release Cylinder Components Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 CLUTCHES Corolla

Fig. 31: Identifying Clutch Release Cylinder Piston Lubrication Points Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS Application Clutch Cover-To-Flywheel Bolt Clutch Line Union Clutch Release Fork Support Crossmember Bolt Bolt "A" Bolt "B" Ft. Lbs. (N.m) 14 (19) 11 (15) 27 (37) 129 (175) 108 (147)

2002 CLUTCHES Corolla

Bolt "C" Bolt "D" Bolt "E" Nut "F" Exhaust Pipe Bolt Exhaust Pipe Support Bracket Bolt/Nut Flywheel Set Bolt Step 1 Step 2 Heat Insulator Bolt Left Engine Mounting Bracket Bolt Left Engine Mounting Bracket Bolt/Nut Left Engine Mounting Stay Bolt Stabilizer Bar Bracket Bolt Stabilizer Cross Brace Starter Bolt Transaxle Filler & Drain Plug Transaxle Mounting Bolt Lower Bolt "A" Lower Bolt "B" Upper Bolt Union Bolt Wheel Lug Nut Clutch Line Bracket Clutch Master Cylinder Nut Clutch Release Cylinder Bleeder Plug Clutch Release Cylinder Bolt & Line Clamps

166 (225) 47 (64) 45 (61) 42 (57) 24 (32) 14 (19) 36 (49) Additional 90 Degrees 12 (17) 38 (52) 64 (87) 15 (21) 108 (147) 51 (69) 28 (38) 29 (39) 17 (23) 35 (47) 47 (64) 18 (25) 76 (103) INCH Lbs. (N.m) 106 (12) 106 (12) 74 (8) 106 (12)

OIL CIRCUIT DIAGRAMS Toyota & Geo A-131L & A-132L

OIL CIRCUIT DIAGRAMS Toyota & Geo A-131L & A-132L

Fig. 1: "P" Range - Park

OIL CIRCUIT DIAGRAMS Toyota & Geo A-131L & A-132L

Fig. 2: "R" Range - Reverse

OIL CIRCUIT DIAGRAMS Toyota & Geo A-131L & A-132L

Fig. 3: "D" Range - 1st Gear

OIL CIRCUIT DIAGRAMS Toyota & Geo A-131L & A-132L

Fig. 4: "D" Range - 2nd Gear

OIL CIRCUIT DIAGRAMS Toyota & Geo A-131L & A-132L

Fig. 5: "D" Range - 3rd Gear (TCC Off)

OIL CIRCUIT DIAGRAMS Toyota & Geo A-131L & A-132L

Fig. 6: "D" Range - 3rd Gear (TCC On)

OIL CIRCUIT DIAGRAMS Toyota & Geo A-131L & A-132L

Fig. 7: "D" Range - 2nd Gear (Kickdown Circuit Applied)

OIL CIRCUIT DIAGRAMS Toyota & Geo A-131L & A-132L

Fig. 8: "2" Range - 2nd Gear

OIL CIRCUIT DIAGRAMS Toyota & Geo A-131L & A-132L

Fig. 9: "L" Range - 1st Gear

2001-02 MANUAL TRANSMISSIONS C59 Overhaul

2001-02 MANUAL TRANSMISSIONS C59 Overhaul

APPLICATION
TRANSAXLE APPLICATION Application Corolla Transaxle Model C59 5-Speed

IDENTIFICATION
TRANSAXLE Transaxle series is listed on certification label located on driver's door post. See Fig. 1 .

Fig. 1: Locating Vehicle Identification Number Plate & Certification Label Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. GEAR RATIOS TRANSAXLE GEAR RATIOS

2001-02 MANUAL TRANSMISSIONS C59 Overhaul

Gear Range C59 1st 2nd 3rd 4th 5th Reverse

Gear Ratio 3.166:1 1.904:1 1.310:1 0.885:1 0.725:1 3.250:1

DESCRIPTION & OPERATION

INTRODUCTION The transaxle is a 5-speed forward/reverse transaxle. Transaxle components consist of input shaft, output shaft, shift shaft and fork assemblies, shift and select lever shaft assembly and differential assembly.

LUBRICATION
NOTE: See appropriate SERVICING article.

TROUBLE SHOOTING
NOTE: Transaxle malfunctions may be caused by poor engine performance, improper adjustments, fluid condition or failure of clutch hydraulics, mechanical or electronic components. Ensure all concerns have been properly checked prior to transaxle overhaul. For mechanical concerns, see MANUAL TRANSMISSION TROUBLE SHOOTING or CLUTCH TROUBLE SHOOTING article in GENERAL INFORMATION.

TRANSAXLE DISASSEMBLY
1. Remove filler plug and drain plug with 2 gaskets. See Fig. 2 . Remove release fork assembly and release bearing. Remove release fork boot and release fork support. Remove bolt and vehicle speed sensor driven gear. See Fig. 3 . Remove back-up light switch. Remove 2 bolts and selecting bellcrank assembly. Remove control bellcrank dust cover from selecting bellcrank assembly. See Fig. 2 . 2. Remove 3 bolts and control lever housing support bracket. See Fig. 3 . Remove 9 transaxle case cover bolts. See Fig. 52 . Using a brass drift and a hammer, carefully tap projection of transaxle case cover to remove case cover from transaxle case. Remove lock bolt. Remove 4 bolts, and pull out shift and select lever shaft assembly with gasket. See Fig. 2 . 3. Engage gear double meshing. Using a chisel and a hammer, loosen staked part of lock nut on output shaft. Remove lock nut. See Fig. 4 . Disengage gear double meshing. Remove bolt from No. 3 gear shift fork. Remove No. 3 hub sleeve and 3 shifting keys with No. 3 gear shift fork. See Fig. 5 . 4. Using a dial indicator, measure 5th gear thrust clearance. See Fig. 6 . Standard clearance is .0039.0224" (.100-.570 mm). Service limit is .0256" (.650 mm). Measure 5th gear radial clearance. See Fig. 7 . Standard clearance is .0006-.0023 (.015-.058). Service limit is .0028" (.070 mm). If clearances exceed specification, replace gear, needle roller bearing or shaft. 5. Using 2 screwdrivers and a hammer, tap out 5th gear snap ring. Using a screwdriver, pry out shifting

2001-02 MANUAL TRANSMISSIONS C59 Overhaul

6.

7. 8.

9.

10.

11.

key spring from No. 3 clutch hub. Install a bolt and washer to the tip of input shaft. Select a bolt with an outer diameter smaller than screw hole of input shaft so that bolt can be turned easily. Using Puller Set (09950-30012), remove No. 3 clutch hub. Using a screwdriver, pry out shifting key spring from other side of No. 3 clutch hub. Remove No. 3 synchronizer ring, 5th gear, needle roller bearing and spacer. Using Puller Set (09950-40011), remove 5th driven gear. Remove 5 bolts and rear bearing retainer. See Fig. 17 . Using snap ring expander, remove 2 snap rings while pulling up on shafts. See Fig. 8 . Remove reverse idler gear shaft lock bolt and gasket. Using 2 screwdrivers and a hammer, remove snap ring from No. 2 shift fork shaft. See Fig. 9 . Using hexagon wrench, remove 3 straight screw plugs. See Fig. 10 . Using magnetic finger, remove 3 seats, springs and balls. Using hexagon wrench, remove lock ball assembly. See Fig. 11 . Remove 16 transaxle case bolts. See Fig. 12 . Using a plastic-faced hammer, carefully tap projection of transaxle case to separate case halves. Remove 2 bolts and oil receiver pipes from transaxle case. See Fig. 47 . Remove reverse idler gear, thrust washer and shaft. Remove 2 bolts and reverse shift arm bracket. See Fig. 13 . Using 2 screwdrivers and a hammer, tap out 3 snap rings from each gear shift fork shaft. Remove No. 1 gear shift head, No. 1 and No. 2 gear shift fork set bolts. See Fig. 14 . Pull up No. 3 gear shift fork shaft, and remove No. 2 gear shift fork shaft. Remove No. 1 gear shift head. See Fig. 15 . Using magnetic finger, remove 2 balls from reverse shift fork. See Fig. 16 . Remove No. 3 gear shift fork shaft and reverse shift fork. Pull out No. 1 gear shift fork shaft from transaxle case. Remove No. 1 and No. 2 gear shift forks. Remove input and output shafts from transaxle case. Remove differential case assembly. See Fig. 3 . Remove magnet from transaxle case. Remove bolt and transaxle case receiver from transaxle case. See Fig. 3 . Using a screwdriver, remove 2 shifting key springs. Remove No. 3 shifting keys (3) from No. 3 clutch hub.

2001-02 MANUAL TRANSMISSIONS C59 Overhaul

Fig. 2: Removing Transaxle Case External Components Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2001-02 MANUAL TRANSMISSIONS C59 Overhaul

Fig. 3: Removing Differential Case Assembly & Bearings Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2001-02 MANUAL TRANSMISSIONS C59 Overhaul

Fig. 4: Removing Output Shaft Lock Nut Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2001-02 MANUAL TRANSMISSIONS C59 Overhaul

Fig. 5: Removing No. 3 Hub Sleeve & No. 3 Gear Shift Fork Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2001-02 MANUAL TRANSMISSIONS C59 Overhaul

Fig. 6: Measuring 5th Gear Thrust Clearance Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2001-02 MANUAL TRANSMISSIONS C59 Overhaul

Fig. 7: Measuring 5th Gear Radial Clearance Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2001-02 MANUAL TRANSMISSIONS C59 Overhaul

Fig. 8: Removing Shaft Bearing Snap Rings Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2001-02 MANUAL TRANSMISSIONS C59 Overhaul

Fig. 9: Removing Reverse Idler Gear Shaft Lock Bolt & Gasket Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2001-02 MANUAL TRANSMISSIONS C59 Overhaul

Fig. 10: Removing Straight Screw Plugs (3) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2001-02 MANUAL TRANSMISSIONS C59 Overhaul

Fig. 11: Removing Lock Ball Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2001-02 MANUAL TRANSMISSIONS C59 Overhaul

Fig. 12: Removing Transaxle Case Bolts (16) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2001-02 MANUAL TRANSMISSIONS C59 Overhaul

Fig. 13: Removing Reverse Shift Arm Bracket Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2001-02 MANUAL TRANSMISSIONS C59 Overhaul

Fig. 14: Removing Snap Rings, Shift Head & Shift Fork Bolts Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2001-02 MANUAL TRANSMISSIONS C59 Overhaul

Fig. 15: Removing No. 1 Gear Shift Head Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2001-02 MANUAL TRANSMISSIONS C59 Overhaul

Fig. 16: Removing 2 Balls From Reverse Shift Fork Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2001-02 MANUAL TRANSMISSIONS C59 Overhaul

Fig. 17: Exploded View Of Transaxle Internal Components Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INSPECTION 1. Check 5th gear synchronizer ring for wear or damage. Check braking effect of synchronizer ring. Turn

2001-02 MANUAL TRANSMISSIONS C59 Overhaul

synchronizer ring in one direction while pushing it to gear cone. See Fig. 18 . Ensure ring locks. If braking effect is insufficient, apply small amount of fine lapping compound between synchronizer ring and gear cone. Lightly rub synchronizer ring and gear cone together. Recheck braking effect. 2. Using feeler gauge, measure clearance between synchronizer ring back and gear spline end. See Fig. 19 . Clearance should be .0236" (.600 mm). If clearance is less than specification, replace synchronizer ring, and apply small amount of fine lapping compound on gear cone. 3. Check gear shift fork and hub sleeve clearance. Using feeler gauge, measure clearance between hub sleeve and shift fork. See Fig. 19 . Clearance should be .039" (1.00 mm). If clearance exceeds specification, replace shift fork or hub sleeve.

Fig. 18: Inspecting Gear Synchronizer Ring Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2001-02 MANUAL TRANSMISSIONS C59 Overhaul

Fig. 19: Measuring Shift Fork & Synchronizer Ring Clearance Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

COMPONENT DISASSEMBLY & REASSEMBLY

REVERSE RESTRICT PIN
Disassembly & Reassembly

2001-02 MANUAL TRANSMISSIONS C59 Overhaul

Using a hexagon wrench, remove straight screw plug. See Fig. 20 . Using a pin punch and a hammer, tap out slotted spring pin. Replace reverse restrict pin. See Fig. 21 . Using a pin punch and a hammer, tap in slotted spring pin. Apply sealant to screw plug threads. Install plug and tighten to specification. See TORQUE SPECIFICATIONS .

Fig. 20: Removing Straight Screw Plug At Reverse Restrict Pin Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2001-02 MANUAL TRANSMISSIONS C59 Overhaul

Fig. 21: Replacing Reverse Restrict Pin Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INPUT & OUTPUT SHAFT BEARINGS & SEALS
Disassembly & Reassembly

1. Using appropriate puller, remove input shaft front bearing from transaxle case. Using appropriate puller, remove oil seal from transaxle case. Using appropriate adapter, driver and a hammer, drive NEW oil seal into transaxle case to a depth of .61-.63" (15.6-16.0 mm). Coat oil seal lip with grease. Using appropriate adapter and a press, install NEW input shaft front bearing into transaxle case. Ensure bearing is installed with square side facing inward. NOTE: When replacing output shaft front bearing, replace bearing inner race with bearing.

2. Remove bolt and bearing lock plate. See Fig. 3 . Using appropriate puller, remove output shaft front bearing from transaxle case. Remove output shaft cover. Inspect cover for damage. Replace as necessary. Install output shaft cover projection into case side hollow. See Fig. 22 .

2001-02 MANUAL TRANSMISSIONS C59 Overhaul

3. Using appropriate adapter and a press, install NEW output shaft front bearing into transaxle case. Ensure bearing is installed with square side facing inward. Install bearing lock plate and bolt. Tighten bolt to specification. See TORQUE SPECIFICATIONS .

Fig. 22: Installing Output Shaft Cover Projection Into Case Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INPUT SHAFT
Disassembly

1. Using a feeler gauge, measure 3rd gear and 4th gear thrust clearances. See Fig. 23 . See INPUT SHAFT CLEARANCE SPECIFICATIONS table. Secure input shaft in soft-jaw vise. Using a dial indicator, measure 3rd gear and 4th gear radial clearance. See Fig. 24 . If any clearance exceeds service limit, replace gear, needle roller bearing and/or shaft.

2001-02 MANUAL TRANSMISSIONS C59 Overhaul

Fig. 23: Measuring 3rd & 4th Gear Thrust Clearance Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2001-02 MANUAL TRANSMISSIONS C59 Overhaul

Fig. 24: Measuring 3rd & 4th Gear Radial Clearance Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 2. Using 2 screwdrivers and a hammer, tap out input shaft snap ring. Using Bearing Remover (0995000020) and a press, remove rear ball bearing. Remove needle roller bearing, spacer and synchronizer ring. See Fig. 26 . 3. Using 2 screwdrivers and a hammer, tap out snap ring. Using bearing remover and a press, remove No. 2 hub sleeve, No. 2 clutch hub assembly, 3rd gear and synchronizer ring. See Fig. 26 . 4. Support input shaft by hand. Remove needle roller bearings. Remove No. 2 hub sleeve from No. 2 clutch hub. Remove No. 2 shifting keys (3) and No. 2 shifting key springs from No. 2 clutch hub. INPUT SHAFT CLEARANCE SPECIFICATIONS Application 3rd Gear Thrust Clearance Standard Service Limit 4th Gear Thrust Clearance Standard Service Limit 3rd & 4th Gear Radial Clearance Standard Service Limit

In. (mm) .0039-.0138 (.100-.350) .0157 (.400) .0039-.0217 (.100-.550) .0236 (.600) .0006-.0023 (.015-.058) .0028 (.070)

2001-02 MANUAL TRANSMISSIONS C59 Overhaul

Inspection

1. Inspect all parts for damage and wear. Thoroughly clean all parts in clean solvent, then dry and lubricate. Ensure oil passages are free of contamination. 2. Check braking effect of synchronizer ring. Turn synchronizer ring in one direction while pushing it to gear cone. See Fig. 18 . Ensure ring locks. If braking effect is insufficient, apply small amount of fine lapping compound between synchronizer ring and gear cone. Lightly rub synchronizer ring and gear cone together. Recheck braking effect. Replace if necessary. 3. Using a feeler gauge, measure clearance between synchronizer ring back and gear spline end. See Fig. 19 . Clearance should be .0236" (.600 mm). If clearance is less than specification, replace synchronizer ring, and apply small amount of fine lapping compound on gear cone. 4. Check gear shift fork and hub sleeve clearance. Using feeler gauge, measure clearance between hub sleeve and shift fork. See Fig. 19 . Clearance should be .039" (1.00 mm). If clearance exceeds specification, replace shift fork or hub sleeve. 5. Measure and record journal diameter of input shaft at points "A", "B", "C" and "D". See Fig. 26 . Replace input shaft if input shaft journal diameter is less than specification. See INPUT SHAFT JOURNAL DIAMETER SPECIFICATIONS table. Support input shaft on "V" blocks. Using a dial indicator, measure runout while rotating input shaft 2 complete revolutions. See Fig. 25 . Runout limit is .0020" (.050 mm). If runout exceeds specification, replace input shaft.

2001-02 MANUAL TRANSMISSIONS C59 Overhaul

Fig. 25: Measuring Input Shaft Runout Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. INPUT SHAFT JOURNAL DIAMETER SPECIFICATIONS Journal Application (1) "A" (5th Gear) "B" (4th Gear) "C" (3rd Gear) "D" (Needle Roller Bearing) (1) "A", "B", "C" and "D" are measuring points. See Fig. 26 .
(2) Minimum journal diameters. (2) In. (mm)

.9791 (24.870) 1.1405 (28.970) 1.2193 (30.970) .9831 (24.970)

2001-02 MANUAL TRANSMISSIONS C59 Overhaul

Fig. 26: Identifying Input Shaft Components Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Reassembly

1. Coat all sliding and rotating surfaces with gear oil. Install No. 2 shifting key springs (3) and No. 2 shifting keys to No. 2 clutch hub. Install No. 2 hub sleeve to No. 2 clutch hub. See Fig. 27 . Ensure components are installed in correct direction. 2. Apply gear oil to needle roller bearing and install it. Install 3rd gear and synchronizer ring. Install No. 2 hub sleeve and No. 2 clutch hub assembly so that synchronizer ring slots and No. 2 shifting keys are aligned. Identify synchronizer ring by the teeth on the synchronizer ring. See Fig. 28 . 3. Using a press, install 3rd gear, No. 2 hub sleeve and No. 2 clutch hub assembly. Select thickest snap ring that allows minimum axial play. See Fig. 29 . See 3RD GEAR HUB SNAP RING SPECIFICATIONS table. Install selected snap ring.

2001-02 MANUAL TRANSMISSIONS C59 Overhaul

Fig. 27: Assembling No. 2 Hub Sleeve & No. 2 Clutch Hub Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2001-02 MANUAL TRANSMISSIONS C59 Overhaul

Fig. 28: Installing Synchronizer Ring, No. 2 Hub Sleeve & No. 2 Clutch Hub Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2001-02 MANUAL TRANSMISSIONS C59 Overhaul

Fig. 29: Selecting Input Shaft Snap Ring (3rd Gear) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 4. Recheck 3rd gear thrust clearance. See INPUT SHAFT CLEARANCE SPECIFICATIONS table. Install spacer. Apply gear oil to needle roller bearing and install it. Place synchronizer ring on No. 2 hub sleeve assembly and align the synchronizer ring slots with No. 2 shifting keys. Install 4th gear. Using appropriate adapter and a press, install rear ball bearing to input shaft. 5. Select thickest snap ring that fits into groove that allows minimum axial play. See Fig. 30 . See 4TH GEAR SNAP RING SPECIFICATIONS table. Install selected snap ring. Recheck 4th gear thrust clearance. See INPUT SHAFT CLEARANCE SPECIFICATIONS table. 3RD GEAR HUB SNAP RING SPECIFICATIONS Identification Mark Thickness - In. (mm) 0 .0906 (2.301)

2001-02 MANUAL TRANSMISSIONS C59 Overhaul

1 2 3 4 5

.0929 (2.359) .0953 (2.421) .0976 (2.479) .1000 (2.540) .1024 (2.601)

4TH GEAR SNAP RING SPECIFICATIONS Identification Mark Thickness - In. (mm) A .0902 (2.291) B .0925 (2.350) C .0949 (2.410) D .0972 (2.469) E .0996 (2.530) F .1020 (2.591)

Fig. 30: Selecting Input Shaft Snap Ring (4th Gear)

2001-02 MANUAL TRANSMISSIONS C59 Overhaul

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. OUTPUT SHAFT

Disassembly

1. Using a feeler gauge, measure 1st and 2nd gear thrust clearances. See Fig. 31 . See OUTPUT SHAFT CLEARANCE SPECIFICATIONS table. Secure output shaft in soft jaw vise. Using a dial indicator, measure 1st and 2nd gear radial clearance. See Fig. 32 . If any clearance exceeds service limit, replace gear, needle roller bearing and/or shaft. 2. Using Bearing Remover (09950-00020) and a press, remove rear ball bearing and 4th driven gear. See Fig. 34 . Support output shaft by hand. Remove output gear spacer. Shift No. 1 hub sleeve into 1st gear. See Fig. 33 . Using bearing remover and press, remove 3rd driven gear and 2nd gear. 3. Remove needle roller bearing, spacer and synchronizer ring. Using 2 screwdrivers and a hammer, tap out snap ring. Using a press, remove reverse gear, No. 1 clutch hub assembly, 1st gear and synchronizer ring. See Fig. 34 . 4. Remove needle roller bearing and 1st gear thrust washer. Using magnetic finger, remove ball. Remove reverse gear from No. 1 clutch hub. Remove No. 1 shifting keys (3) and No. 1 shifting key springs from No. 1 clutch hub. See Fig. 34 . OUTPUT SHAFT CLEARANCE SPECIFICATIONS Application 1st Gear Thrust Clearance Standard Service Limit 2nd Gear Thrust Clearance Standard Service Limit 1st & 2nd Gear Radial Clearance Standard Service Limit

In. (mm) .0039-.0157 (.100-.400) .0177 (.450) .0039-.0177 (.100-.450) .0197 (.500) .0006-.0023 (.015-.058) .0028 (.070)

2001-02 MANUAL TRANSMISSIONS C59 Overhaul

Fig. 31: Measuring 1st & 2nd Gear Thrust Clearance Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2001-02 MANUAL TRANSMISSIONS C59 Overhaul

Fig. 32: Measuring 1st & 2nd Gear Radial Clearance Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2001-02 MANUAL TRANSMISSIONS C59 Overhaul

Fig. 33: Shifting No. 1 Hub Sleeve Into 1st Gear Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2001-02 MANUAL TRANSMISSIONS C59 Overhaul

Fig. 34: Identifying Output Shaft Components Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Inspection

1. Inspect all parts for damage and wear. Replace if necessary. Thoroughly clean all parts in clean solvent, then dry and lubricate all parts. Ensure oil passages are free of contamination. 2. Check for wear or damaged synchronizer ring. Check braking effect of synchronizer ring. Turn

2001-02 MANUAL TRANSMISSIONS C59 Overhaul

synchronizer ring in one direction while pushing it to gear cone. See Fig. 18 . Ensure ring locks. If braking effect is insufficient, apply small amount of fine lapping compound between synchronizer ring and gear cone. Lightly rub synchronizer ring and gear cone together. Recheck braking effect. Replace if necessary. 3. Using feeler gauge, measure clearance between synchronizer ring back and gear spline end. See Fig. 19 . Clearance should be .0236" (.600 mm). If clearance is less than specification, replace synchronizer ring, and apply small amount of fine lapping compound on gear cone. 4. Using feeler gauge, measure clearance between reverse gear and gear shift fork. See Fig. 19 . Clearance should be .039" (1.00 mm). If clearance exceeds specification, replace gear shift fork or reverse gear. 5. Check output shaft for wear or damage. Using a micrometer, measure and record outside journal diameter of output shaft at points "A", "B" and "C". See Fig. 34 . If outer journal diameter is less than minimum, replace output shaft. Using a dial indicator, measure runout while rotating output shaft 2 complete revolutions. See Fig. 35 . Maximum runout is .0020" (.050 mm). Replace output shaft if runout on any part of shaft is not within specification. See OUTPUT SHAFT JOURNAL DIAMETER SPECIFICATIONS table. OUTPUT SHAFT JOURNAL DIAMETER SPECIFICATIONS Journal Application (1) "A" (Needle Roller Bearing) "B" (1st Gear) "C" (2nd Gear) (1) "A", "B" and "C" are measuring points. See Fig. 34 .
(2) Minimum diameter. (2) In. (mm)

1.2980 (32.970) 1.4949 (37.970) 1.2587 (31.970)

2001-02 MANUAL TRANSMISSIONS C59 Overhaul

Fig. 35: Measuring Output Shaft Runout Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Reassembly

1. Coat all sliding and rotating surfaces with gear oil. Install No. 1 shifting key springs (3) and No. 1 shifting keys to No. 1 clutch hub. Install No. 1 clutch hub to reverse gear. Ensure reverse gear and No. 1 clutch hub are installed in correct direction. See Fig. 36 . 2. Using magnetic finger, install ball into output shaft. Fit 1st gear thrust washer groove securely over locking ball when installing thrust washer on output shaft. Apply gear oil to needle roller bearing and install needle roller bearing. Install 1st gear and synchronizer ring. See Fig. 37 . Place synchronizer ring on 1st gear and align clutch hub grooves with projections on synchronizer ring. See Fig. 38 . 3. Using a press, install 1st gear and reverse gear. Select thickest snap ring that allows minimum axial play. See Fig. 39 . See 1ST GEAR SNAP RING SPECIFICATIONS table. Install selected snap ring. Using a screwdriver and a hammer, tap in snap ring. Recheck 1st gear thrust clearance. See

2001-02 MANUAL TRANSMISSIONS C59 Overhaul

OUTPUT SHAFT CLEARANCE SPECIFICATIONS table. 4. Place synchronizer ring on gear and align clutch hub grooves with projections on synchronizer ring. Install spacer. Apply gear oil to needle roller bearing and install it. Install 2nd gear. Using press, install 3rd driven gear. 5. Recheck 2nd gear thrust clearance. See OUTPUT SHAFT CLEARANCE SPECIFICATIONS table. Install output gear spacer. Using a press, install 4th driven gear. Using appropriate adapter and a press, install rear ball bearing.

Fig. 36: Assembling Reverse Gear & No. 1 Clutch Hub Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 1ST GEAR SNAP RING SPECIFICATIONS Identification Mark A B C D E F

Thickness - In. (mm) .098 (2.49) .100 (2.54) .103 (2.62) .105 (2.68) .108 (2.74) .110 (2.80)

2001-02 MANUAL TRANSMISSIONS C59 Overhaul

Fig. 37: Installing 1st Gear, Needle Roller Bearing & Synchronizer Ring Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2001-02 MANUAL TRANSMISSIONS C59 Overhaul

Fig. 38: Aligning Clutch Hub Grooves With Synchronizer Ring Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2001-02 MANUAL TRANSMISSIONS C59 Overhaul

Fig. 39: Selecting Output Shaft Snap Ring At 1st Gear Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. SHIFT & SELECT LEVER SHAFT
Disassembly

Remove "E" ring, No. 2 select spring seat and spring. Drive out roll pin from No. 2 shift inner lever. Remove No. 2 shift inner lever. Drive out roll pin from No. 1 shift inner lever and remove lever and shift interlock plate. See Fig. 40 . Drive out roll pin from select inner lever. Remove select inner lever, spring seat, spring and No. 1 select spring seat. Remove snap ring from lever shaft. Remove control shaft cover.
Inspection & Reassembly

If necessary, replace control shaft cover oil seal. Pry oil seal out of cover. Using socket or appropriate drive adapter and hammer, drive in NEW oil seal. Install to depth of .039-.079" (1.00-2.00 mm). Coat lip of oil seal with grease. Apply grease to shaft. Install components in reverse order of disassembly.

2001-02 MANUAL TRANSMISSIONS C59 Overhaul

Fig. 40: Exploded View Of Shift & Select Lever Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. DIFFERENTIAL ASSEMBLY
Disassembly

1. Place match marks on ring gear and differential case for reassembly reference. Remove 8 bolts. Using a copper hammer, tap ring gear and remove from differential case. See Fig. 41 . 2. On vehicle speed sensor drive gear side, remove tapered roller bearing from differential case using appropriate puller. Remove vehicle speed sensor drive gear. On ring gear side, remove tapered roller bearing from differential case using appropriate puller. Set puller claws at indentation locations on differential case. 3. Using a dial indicator, measure and record backlash of one side gear while holding one pinion toward case. Backlash should be .002-.008" (.05-.20 mm). See Fig. 42 . If backlash is incorrect, drive out pinion shaft straight pin from ring gear side of case. Remove pinion shaft from differential case. Remove pinion gears, side gears and thrust washers from case. Inspect components for damage or wear. Replace as needed. 4. On transaxle case cover side of transaxle case, using appropriate driver and a hammer, tap out oil seal. Using appropriate puller, remove tapered roller bearing outer race and shim (if necessary). On differential assembly side of transaxle case, using a screwdriver and a hammer, drive out oil seal. Using appropriate puller, remove tapered roller bearing outer race and shim (if necessary).
Reassembly

2001-02 MANUAL TRANSMISSIONS C59 Overhaul

1. On transaxle case cover side of transaxle case, using appropriate driver and a hammer, tap in NEW oil seal to a depth of .083-.106" (2.10-2.70 mm). Coat oil seal lip with grease. If tapered roller bearing was replaced, install NEW selected shim into transaxle case. If tapered roller bearing was not replaced, install original shim into transaxle case. Using appropriate adapter and a press, install tapered roller bearing outer race into transaxle case. 2. On differential assembly side of transaxle case, install shim into transaxle case. Using appropriate adapter and a press, install tapered roller bearing outer race. Using appropriate driver and a hammer, tap in oil seal to a depth of .062-.087" (1.60-2.20 mm). Coat oil seal lip with grease. 3. If backlash was incorrect during disassembly inspection, select NEW side gear thrust washers to correct backlash. Side gear thrust washers are available in thicknesses from .0374" (.950 mm) to .0472" (1.199 mm), in .002" (.05 mm) increments. 4. Install thrust washers of equal thickness to side gears. Install side gears with thrust washers, pinion thrust washers and pinions gears into differential case. Install pinion shaft. Recheck side gear backlash while holding one pinion gear toward case. Backlash should be .002-.008" (.05-.20 mm). Correct as needed. Using a pin punch and a hammer, tap in pinion shaft straight pin through differential case and hole in pinion shaft. Using a chisel and a hammer, stake pin holes around circumference of differential case. 5. On ring gear side, using appropriate adapter and a press, install tapered roller bearing. On vehicle speed sensor drive gear side, place drive gear in position to stop turning, and install drive gear. Ensure drive gear is installed in correct direction. See Fig. 43 . Using appropriate adapter and a press, install tapered roller bearing. Clean contact surface of differential case. Heat ring gear to 212F (100C) in boiling water. Remove ring gear from water. After moisture on ring gear has completely evaporated, install ring gear onto differential case. 6. Align match marks on ring gear and differential case. Temporarily install 8 set bolts. Once ring gear has cooled sufficiently, tighten bolts to specification. See TORQUE SPECIFICATIONS .

Fig. 41: Exploded View Of Differential Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2001-02 MANUAL TRANSMISSIONS C59 Overhaul

Fig. 42: Checking Side Gear Backlash Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2001-02 MANUAL TRANSMISSIONS C59 Overhaul

Fig. 43: Installing Vehicle Speed Sensor Drive Gear Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

TRANSAXLE ADJUSTMENTS
DIFFERENTIAL BEARING PRELOAD 1. Install differential assembly in transaxle case. Install transaxle case halves with 16 bolts, and tighten to 21 ft. lbs. (29 N.m). 2. Using Differential Preload Adapter (09564-32011) and an INCH-lb. torque wrench, rotate differential assembly right and left several times to seat bearings. Measure differential side bearing starting torque (preload). See Fig. 44 . Starting torque should be 7-14 INCH lbs. (.8-1.6 N.m) for NEW bearing and 4.3-8.7 INCH lbs. (.5-1.0 N.m) for used bearing. 3. If starting torque (preload) is not within specification, remove transaxle case differential side bearing outer race. Select NEW adjusting shim. See Fig. 41 . See DIFFERENTIAL PRELOAD SHIMS table. Preload will change about 2.6-3.5 INCH lbs. (.3-.4 N.m) with each shim thickness change. Shims are available in .002" (.05 mm) increments. Install selected shim and outer race in transaxle case. Recheck differential bearing preload. DIFFERENTIAL PRELOAD SHIMS Identification Mark Thickness - In. (mm) A .0827 (2.101) B .0846 (2.149) C .0866 (2.200) D .0886 (2.250) E .0906 (2.301) F .0925 (2.350) G .0945 (2.400) H .0965 (2.451) J .0984 (2.499)

2001-02 MANUAL TRANSMISSIONS C59 Overhaul

K L M N P Q R S T U

.1004 (2.550) .1024 (2.601) .1043 (2.649) .1063 (2.700) .1083 (2.751) .1102 (2.799) .1122 (2.850) .1142 (2.901) .1161 (2.949) .1181 (3.000)

Fig. 44: Measuring Differential Bearing Preload Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

TRANSAXLE REASSEMBLY
1. Coat all sliding and rotating surfaces with gear oil before assembly. Check differential side bearing preload. See DIFFERENTIAL BEARING PRELOAD under TRANSAXLE ADJUSTMENTS. 2. Install No. 3 clutch hub and 3 shifting keys to hub sleeve. Install 2 key springs to hub. Position key springs so that their end gaps are not aligned. Install No. 3 clutch hub into No. 3 hub sleeve. See Fig. 17 . Install magnet to transaxle case. Install differential case assembly. See Fig. 3 . Install input and output shafts into transaxle case.

2001-02 MANUAL TRANSMISSIONS C59 Overhaul

3. Place No. 1 and No. 2 shift forks into groove of No. 1 and No. 2 hub sleeves. Install No. 1 shift fork shaft into No. 1 shift fork hole. Install 2 set bolts of No. 1 and No. 2 shift forks. 4. Install 2 balls to hole of reverse shift fork. See Fig. 16 . Install No. 3 shift fork to reverse shift fork. Using a screwdriver and a hammer, install snap ring. Install No. 3 shift fork shaft with reverse shift fork into transaxle case. See Fig. 17 . 5. Place shift head down, and install No. 2 shift fork shaft. See Fig. 15 . To avoid interference of 2 balls, lift up No. 3 shift fork shaft. See Fig. 45 . Install No. 2 shift fork shaft until it contacts transaxle case. Install No. 2 shift fork and shift head to No. 2 shift fork shaft, and tighten bolts to specification. See TORQUE SPECIFICATIONS . 6. Using a screwdriver and a hammer, install 2 NEW snap rings to No. 1 and No. 3 shift fork shafts. When installing reverse idler gear, thrust washer and shaft, align alignment mark. See Fig. 46 . When installing reverse shift arm bracket, set pin on top of reverse shift arm into groove on reverse idler gear. Fit the claw of reverse shift arm bracket with notch of input shaft front bearing. See Fig. 13 . Apply FIPG (08826-00090) to transaxle case and install 16 bolts. See Fig. 51 . 7. Apply Loctite 242 to lock ball assembly threads. Using hexagon wrench, install lock ball assembly. See Fig. 11 . Install 3 balls, springs and seats. Apply sealant to threads, and install 3 straight screw plugs. See Fig. 10 . 8. Install snap ring to No. 2 shift fork shaft. Install reverse idler gear shaft lock bolt. See Fig. 9 . Using snap ring expander, install 2 snap rings while pulling up on shafts. See Fig. 8 . Install rear bearing retainer. Apply Loctite 242 to retainer bolt threads and install bolts. Tighten bolts to specification. See TORQUE SPECIFICATIONS . 9. When installing oil receiver pipes, prevent pipes from being deformed. Install oil receiver pipes while placing them against transaxle case. See Fig. 47 . Using 5th Driven Gear Replacer (09309-12020), install 5th driven gear. See Fig. 48 . Install spacer, needle roller bearing, 5th gear and synchronizer ring. 10. Using Upper Ball Joint Dust Cover Replacer (09636-20010) and hammer, drive in No. 3 clutch hub and sleeve assembly with No. 3 shift fork. When installing No. 3 clutch hub assembly, align synchronizer ring slots with No. 3 shifting keys. Ensure 3rd clutch hub assembly is installed in correct direction. See Fig. 49 . Install bolt to No. 3 shift fork. 11. Using a dial indicator, check 5th gear thrust clearance. See Fig. 6 . Standard thrust clearance should be .0039-.0224" (.099-.569 mm). Service limit thrust clearance is .0256" (.650 mm). Select snap ring that allows minimum axial play. See 5TH GEAR SNAP RING THICKNESS CHART table. Using a screwdriver and a hammer, install selected snap ring. 12. Engage gear double meshing. Install NEW lock nut. See Fig. 4 . Disengage gear double meshing. Install shift and select lever shaft assembly with NEW gasket. Apply sealant to "A" bolt threads. See Fig. 50 . Install 4 bolts and lock bolt. 13. Apply FIPG (08826-00090) to transaxle case cover, and install cover and 9 bolts. See Fig. 52 . Install control lever housing support bracket and 3 bolts. Install selecting bellcrank assembly and 2 bolts. See Fig. 2 . 14. Install back-up light switch. Install vehicle speed sensor driven gear and bolt. Install release fork assembly and release bearing. Install release fork support and fork boot. See Fig. 3 .

2001-02 MANUAL TRANSMISSIONS C59 Overhaul

Fig. 45: Lifting Up No. 3 Gear Shift Fork Shaft Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2001-02 MANUAL TRANSMISSIONS C59 Overhaul

Fig. 46: Aligning Reverse Idler Gear, Thrust Washer & Shaft Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2001-02 MANUAL TRANSMISSIONS C59 Overhaul

Fig. 47: Installing Oil Receiver Pipes Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2001-02 MANUAL TRANSMISSIONS C59 Overhaul

Fig. 48: Installing 5th Driven Gear Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2001-02 MANUAL TRANSMISSIONS C59 Overhaul

Fig. 49: Installing No. 3 Hub Sleeve & No. 3 Clutch Assembly Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 50: Identifying Shift & Select Lever Shaft Bolt Sealant Locations Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2001-02 MANUAL TRANSMISSIONS C59 Overhaul

Fig. 51: Identifying Transaxle Case Sealant & Bolt Locations Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2001-02 MANUAL TRANSMISSIONS C59 Overhaul

Fig. 52: Identifying Transaxle Case Cover Sealant & Bolt Locations Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. 5TH GEAR SNAP RING THICKNESS CHART Identification Mark A B C D E F G

In. (mm) .0886 (2.250) .0909 (2.310) .0933 (2.370) .0957 (2.430) .0980 (2.490) .1004 (2.550) .1028 (2.610)

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS Application Back-Up Light Switch Clutch Release Fork Support Bolt Drain & Filler Plug Lock Ball Assembly Lock Bolt No. 1 Gear Shift Head Bolt Ft. Lbs. (N.m) 30 (40) 27 (37) 29 (39) 29 (39) 21 (29) 12 (16)

2001-02 MANUAL TRANSMISSIONS C59 Overhaul

No. 3 Gear Shift Fork Bolt Oil Receiver Pipe Bolt Output Shaft Lock Nut Rear Bearing Retainer Bolt Reverse Idler Gear Shaft Lock Bolt Reverse Shift Arm Bracket Bolt Ring Gear Set Bolt Selecting Bellcrank Assembly Bolt Shift Fork Set Bolt Shift & Select Lever Shaft Assembly Bolt Straight Screw Plug At Reverse Restrict Pin At Shift Fork Shaft Transaxle Case Bolt Transaxle Case Cover Bolt Transaxle (Differential) Case Bolt Control Lever Housing Support Bracket Bolt Output Shaft Front Bearing Lock Plate Bolt Transaxle Case Receiver Bolt Vehicle Speed Sensor Drive Gear Bolt

16 (22) 13 (18) 87 (118) 20 (27) 21 (29) 13 (18) 57 (77) 18 (25) 12 (16) 15 (20) 10 (13) 18 (25) 21 (29) 13 (18) 21 (29) INCH Lbs. (N.m) 97 (11) 97 (11) 97 (11) 97 (11)

TRANSAXLE SPECIFICATIONS
TRANSAXLE SPECIFICATIONS Application Gear Radial Clearance 1st & 2nd Gear Standard Service Limit 3rd & 4th Gear Standard Service Limit 5th Gear Standard Service Limit Gear Thrust Clearances 1st Gear Standard Service Limit 2nd Gear Standard Service Limit 3rd Gear In. (mm)

.0006-.0023 (.015-.058) .0028 (.070) .0006-.0023 (.015-.058) .0028 (.070) .0006-.0023 (.015-.058) .0023 (.058)

.0039-.0157 (.100-.400) .0177 (.450) .0039-.0177 (.100-.450) .0197 (.500)

2001-02 MANUAL TRANSMISSIONS C59 Overhaul

Standard Service Limit 4th Gear Standard Service Limit 5th Gear Standard Service Limit Hub Sleeve-To-Shift Fork Clearance (Maximum) Input & Output Shaft Runout (Maximum) Pinion Gear Backlash Synchronizer-To-Gear Clearance (Minimum)

.0039-.0138 (.100-.350) .0157 (.400) .0039-.0217 (.100-.550) .0236 (.600) .0039-.0224 (.100-.570) .0256 (.650) .039 (1.00) .0020 (.050) .002-.008 (.05-.20) .0236 (.600)

2002 MANUAL TRANSMISSIONS Servicing - Toyota

2002 MANUAL TRANSMISSIONS Servicing - Toyota

APPLICATION
TRANSAXLE/TRANSMISSION APPLICATION Application Camry Celica Corolla ECHO RAV4 AWD FWD Solara 2.4L 3.0L Tacoma RWD 2.4L 4-Cyl. 3.4L V6 4WD 2.7L 4-Cyl. 3.4L V6 Tundra RWD 4WD TRANSFER CASE APPLICATION Application RAV4 Tacoma 2.7L 4-Cyl 3.4L V6 Tundra (1) Transfer case is not identified by model. Trans. Model E351 5-Speed C59 5-Speed Or C60 6-Speed C59 5-Speed C150 5-Speed E352F 5-Speed E352 5-Speed E351 5-Speed E153 5-Speed

W59 5-Speed R150 5-Speed W59 5-Speed R150F 5-Speed R150 5-Speed R150F 5-Speed

Transfer Case Model MV2AV

(1) w/W59 (1) w/R150F

VF2A

LUBRICATION
SERVICE INTERVALS
Transaxle/Transmission

Check transmission fluid level every 30,000 miles or 24 months. Service interval is not available for

2002 MANUAL TRANSMISSIONS Servicing - Toyota

vehicles operated under normal conditions. Under severe conditions such as trailer towing, police, taxi, local delivery service or operating under dusty conditions, replace transmission fluid every 30,000 miles or 24 months.
Transfer Case

Check transfer case fluid level every 15,000 miles or 12 months. Service interval is not available for vehicles operated under normal conditions. Under severe conditions such as trailer towing, police, taxi, local delivery service or operating under dusty conditions, replace transfer case fluid every 30,000 miles or 24 months, except on RAV4 which requires changing every 15,000 miles or 12 months. CHECKING FLUID LEVELS
Transaxle/Transmission

Raise and support the vehicle. Ensure vehicle is level. Remove fill plug from transaxle/transmission. Fluid should be level with bottom edge of fill plug hole. See Fig. 1 -Fig. 3 . If fluid is low, fill with appropriate fluid until fluid is level with fill plug opening. See RECOMMENDED FLUIDS . Reinstall fill plug. Tighten to specification. See TORQUE SPECIFICATIONS .

Fig. 1: Checking Transaxle Fluid (Camry, Celica, Corolla, RAV4 - 2WD & Solara) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 MANUAL TRANSMISSIONS Servicing - Toyota

Fig. 2: Checking Transaxle Fluid Level (RAV4 - AWD) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 MANUAL TRANSMISSIONS Servicing - Toyota

Fig. 3: Checking Transmission Fluid Level (Tacoma & Tundra) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
Transfer Case (RAV4, Tacoma & Tundra)

Raise and support the vehicle. Ensure vehicle is level. Remove fill plug located on rear of transfer case. See Fig. 4 . Fluid should be level with bottom edge of fill plug hole. If fluid is low, fill with appropriate fluid until fluid is level with fill plug opening. See RECOMMENDED FLUIDS . Reinstall fill plug.

2002 MANUAL TRANSMISSIONS Servicing - Toyota

Fig. 4: Checking Transfer Case Fluid Level Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. RECOMMENDED FLUIDS RECOMMENDED FLUIDS Application Transaxle/Transmission Transfer Case FLUID CAPACITIES TRANSAXLE/TRANSMISSION REFILL CAPACITIES Application Camry & Solara 2.4L 4-Cylinder 3.0L V6 Celica 5-Speed 6-Speed Corolla

Fluid Type SAE 75W-90/API GL-5 Gear Oil SAE 75W-90/API GL-5 Gear Oil

Qts. (L) 2.7 (2.5) 4.4 (4.2) 2.0 (1.9) 2.4 (2.3) 2.0 (1.9)

2002 MANUAL TRANSMISSIONS Servicing - Toyota

ECHO RAV4 2WD 4WD Tacoma RWD 4WD 2.7L 4-Cylinder 3.4L V6 Tundra 2WD 4WD TRANSFER CASE REFILL CAPACITIES Application RAV4 Tacoma & Tundra DRAINING & REFILLING
Except Tacoma & Tundra

2.0 (1.9) 2.6 (2.5) 3.6 (3.4) 2.7 (2.6) 2.6 (2.5) 2.3 (2.2) 2.7 (2.6) 2.3 (2.2)

Qts. (L) .95 (.9) 1.1 (1.0)

Raise and support vehicle. Clean area around drain and fill plugs of any dirt or debris. Remove drain plug and drain fluid into a suitable container. Install a NEW gasket on drain plug and install. Tighten to specification. See TORQUE SPECIFICATIONS . Remove fill plug. See Fig. 1 -Fig. 2 . Fill transaxle to capacity with appropriate fluid. See RECOMMENDED FLUIDS . Install fill plug with a NEW gasket and tighten to specification. See TORQUE SPECIFICATIONS .
Tacoma & Tundra

Raise and support vehicle. Clean area around drain and fill plugs of any dirt or debris. Remove drain plug and drain fluid into a suitable container. Install a NEW gasket on drain plug and install. Tighten to specification. See TORQUE SPECIFICATIONS . Remove fill plug. See Fig. 3 . Fill transmission to capacity with appropriate fluid. See RECOMMENDED FLUIDS . Install fill plug with a NEW gasket and tighten to specification. See TORQUE SPECIFICATIONS .

ADJUSTMENTS
WARNING: Vehicle is equipped with Supplemental Inflatable Restraint (SIR) system. When servicing vehicle, use care to avoid accidental air bag deployment. SIR system-related components are located in various locations throughout interior and exterior of vehicle, depending on application. Do not use electrical test equipment on or near these circuits. If necessary, deactivate SIR system before servicing

2002 MANUAL TRANSMISSIONS Servicing - Toyota

components. See AIR BAG DEACTIVATION PROCEDURES article in GENERAL INFORMATION. SHIFT CONTROL CABLE NOTE: Manufacturer does not provide shift control cable adjustment procedures.

REMOVAL & INSTALLATION

WARNING: Vehicle is equipped with Supplemental Inflatable Restraint (SIR) system. When servicing vehicle, use care to avoid accidental air bag deployment. SIR system-related components are located in various locations throughout interior and exterior of vehicle, depending on application. Do not use electrical test equipment on or near these circuits. If necessary, deactivate SIR system before servicing components. See AIR BAG DEACTIVATION PROCEDURES article in GENERAL INFORMATION. CAUTION: When battery is disconnected, vehicle computer and memory systems may lose memory data. Driveability problems may exist until computer systems have completed a relearn cycle. See COMPUTER RELEARN PROCEDURES article in GENERAL INFORMATION before disconnecting battery. BACK-UP LIGHT SWITCH
Removal & Installation (Camry & Solara)

Raise and support vehicle. Disconnect the wiring harness connector. Remove back-up light switch. See Fig. 5. Install back-up light switch into transaxle case. Install wiring harness connector. Lower vehicle and test switch operation.

2002 MANUAL TRANSMISSIONS Servicing - Toyota

Fig. 8: Removing & Installing Back-Up Light Switch (Tacoma & Tundra) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. SHIFT CONTROL CABLE NOTE: Manufacturer does not provide removal and installation procedure of shift control cable. Only an exploded view is given. See Fig. 9 -Fig. 13 .

2002 MANUAL TRANSMISSIONS Servicing - Toyota

Fig. 9: Exploded View Of Shift Cables & Related Components (Camry & Corolla) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 MANUAL TRANSMISSIONS Servicing - Toyota

Fig. 13: Exploded View Of Shift Cables & Related Components (RAV4) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC. VEHICLE SPEED SENSOR NOTE: Manufacturer does not provide removal and installation procedures for Camry. Vehicle speed sensor is also referred to as VSS assembly.

NOTE:

Removal & Installation

1. Raise and support vehicle. Remove engine under covers or splash shield, if equipped. Disconnect VSS wiring harness connector. Remove bolt and remove VSS assembly. See Fig. 14 -Fig. 17 . Remove and discard "O" ring.

2002 MANUAL TRANSMISSIONS Servicing - Toyota

2. To install, place NEW "O" ring on VSS and install assembly into transaxle. Install bolt and tighten to specification. See TORQUE SPECIFICATIONS . Connect the wiring harness connector. Install engine under covers and/or splash shield, if removed.

Fig. 14: Removing & Installing Vehicle Speed Sensor (Celica & Solara) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 MANUAL TRANSMISSIONS Servicing - Toyota

Fig. 15: Removing & Installing Vehicle Speed Sensor (Corolla & ECHO) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

2002 MANUAL TRANSMISSIONS Servicing - Toyota

Fig. 17: Removing & Installing Vehicle Speed Sensor (Tacoma & Tundra) Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS Application Back-Up Light Switch Except Tacoma & Tundra Tacoma W59 R150 R150F Ft. Lbs. (N.m) 30 (40) 30 (40) 32 (44) 32 (44)

2002 MANUAL TRANSMISSIONS Servicing - Toyota

Tundra Transaxle/Transmission Drain & Fill Plug Camry Celica Corolla ECHO RAV4 Solara Tacoma Tundra Vehicle Speed Sensor Celica Corolla ECHO RAV4 Solara E153 E351 Tacoma Tundra

32 (44) 36 (49) 29 (39) 29 (39) 29 (39) 36 (49) 36 (49) 27 (37) 27 (37) INCH Lbs. (N.m) 97 (11) 97 (11) 97 (11) 150 (17) 150 (17) 49 (5.5) 97 (11) 97 (11)

2002 SYSTEM WIRING DIAGRAMS TOYOTA Corolla

Fig. 1: Heater Circuit

2002 SYSTEM WIRING DIAGRAMS TOYOTA Corolla

Fig. 2: Manual A/C Circuit (1 of 2)

2002 SYSTEM WIRING DIAGRAMS TOYOTA Corolla

Fig. 3: Manual A/C Circuit (2 of 2)

ANTI-LOCK BRAKES

2002 SYSTEM WIRING DIAGRAMS TOYOTA Corolla

Fig. 4: Anti-lock Brake Circuits

COMPUTER DATA LINES

2002 SYSTEM WIRING DIAGRAMS TOYOTA Corolla

Fig. 5: Computer Data Lines

COOLING FAN

2002 SYSTEM WIRING DIAGRAMS TOYOTA Corolla

Fig. 6: Cooling Fan Circuit

CRUISE CONTROL

2002 SYSTEM WIRING DIAGRAMS TOYOTA Corolla

Fig. 7: Cruise Control Circuit

DEFOGGERS

2002 SYSTEM WIRING DIAGRAMS TOYOTA Corolla

Fig. 8: Defogger Circuit

ENGINE PERFORMANCE

2002 SYSTEM WIRING DIAGRAMS TOYOTA Corolla

1.8L

Fig. 9: 1.8L, Engine Performance Circuits, 3 Speed A/T & M/T (1 of 3)

2002 SYSTEM WIRING DIAGRAMS TOYOTA Corolla

Fig. 10: 1.8L, Engine Performance Circuits, 3 Speed A/T & M/T (2 of 3)

2002 SYSTEM WIRING DIAGRAMS TOYOTA Corolla

Fig. 11: 1.8L, Engine Performance Circuits, 3 Speed A/T & M/T (3 of 3)

2002 SYSTEM WIRING DIAGRAMS TOYOTA Corolla

Fig. 12: 1.8L, Engine Performance Circuits, 4 Speed A/T (1 of 3)

2002 SYSTEM WIRING DIAGRAMS TOYOTA Corolla

Fig. 13: 1.8L, Engine Performance Circuits, 4 Speed A/T (2 of 3)

2002 SYSTEM WIRING DIAGRAMS TOYOTA Corolla

Fig. 14: 1.8L, Engine Performance Circuits, 4 Speed A/T (3 of 3)

EXTERIOR LIGHTS

2002 SYSTEM WIRING DIAGRAMS TOYOTA Corolla

Fig. 15: Back-up Lamps Circuit

2002 SYSTEM WIRING DIAGRAMS TOYOTA Corolla

Fig. 16: Exterior Lamps Circuit

GROUND DISTRIBUTION

2002 SYSTEM WIRING DIAGRAMS TOYOTA Corolla

Fig. 17: Ground Distribution Circuit (1 of 3)

2002 SYSTEM WIRING DIAGRAMS TOYOTA Corolla

Fig. 18: Ground Distribution Circuit (2 of 3)

2002 SYSTEM WIRING DIAGRAMS TOYOTA Corolla

Fig. 19: Ground Distribution Circuit (3 of 3)

HEADLIGHTS

2002 SYSTEM WIRING DIAGRAMS TOYOTA Corolla

Fig. 20: Headlight Circuit, Canada

2002 SYSTEM WIRING DIAGRAMS TOYOTA Corolla

Fig. 21: Headlight Circuit, USA

HORN

2002 SYSTEM WIRING DIAGRAMS TOYOTA Corolla

Fig. 22: Horn Circuit

INSTRUMENT CLUSTER

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Fig. 23: Instrument Cluster Circuit

INTERIOR LIGHTS

2002 SYSTEM WIRING DIAGRAMS TOYOTA Corolla

Fig. 24: Courtesy Lamps Circuit

2002 SYSTEM WIRING DIAGRAMS TOYOTA Corolla

Fig. 25: Instrument Illumination Circuit

POWER DISTRIBUTION

2002 SYSTEM WIRING DIAGRAMS TOYOTA Corolla

Fig. 26: Power Distribution Circuit (1 of 2)

2002 SYSTEM WIRING DIAGRAMS TOYOTA Corolla

Fig. 27: Power Distribution Circuit (2 of 2)

POWER DOOR LOCKS

2002 SYSTEM WIRING DIAGRAMS TOYOTA Corolla

Fig. 28: Power Door Lock Circuit, NUMMI Made

2002 SYSTEM WIRING DIAGRAMS TOYOTA Corolla

Fig. 29: Power Door Lock Circuit, TMMC Made

POWER MIRRORS

2002 SYSTEM WIRING DIAGRAMS TOYOTA Corolla

Fig. 30: Power Mirror Circuit

POWER TOP/SUNROOF

2002 SYSTEM WIRING DIAGRAMS TOYOTA Corolla

Fig. 31: Moonroof Circuit

POWER WINDOWS

2002 SYSTEM WIRING DIAGRAMS TOYOTA Corolla

Fig. 32: Power Window Circuit

RADIO

2002 SYSTEM WIRING DIAGRAMS TOYOTA Corolla

Fig. 33: Radio Circuits

SHIFT INTERLOCKS

2002 SYSTEM WIRING DIAGRAMS TOYOTA Corolla

Fig. 34: Shift Interlock Circuit

STARTING/CHARGING

2002 SYSTEM WIRING DIAGRAMS TOYOTA Corolla

Fig. 35: Charging Circuit

2002 SYSTEM WIRING DIAGRAMS TOYOTA Corolla

Fig. 36: Starting Circuit

SUPPLEMENTAL RESTRAINTS

2002 SYSTEM WIRING DIAGRAMS TOYOTA Corolla

Fig. 37: Supplemental Restraint Circuit

TRANSMISSION

2002 SYSTEM WIRING DIAGRAMS TOYOTA Corolla

Fig. 38: A/T Circuit

WARNING SYSTEMS

2002 SYSTEM WIRING DIAGRAMS TOYOTA Corolla

Fig. 39: Warning System Circuits

WIPER/WASHER

2002 SYSTEM WIRING DIAGRAMS TOYOTA Corolla

Fig. 40: Wiper/Washer Circuit